IMIESA July 2025

www.imesa.org.za

IMESA The official magazine of the Institute of Municipal Engineering of Southern Africa

INFRASTRUCTURE DEVELOPMENT • SERVICE DELIVERY • ROADS • BUILDING • MAINTENANCE • ENERGY • WASTE

INDUSTRY INSIGHT

BITUMEN & ASPHALT

SAT: A new era of excellence

Peter Telle

CEO of Ultra Control Valves

Harnessing the energy of water to optimise valve performance

INFORMATION & COMMUNICATIONS TECHNOLOGY

The transformative nexus of AI, BIM, and digital twinning

RESERVOIRS

Innovative developments in precast water storage

takes material handling to the next level

IN THE HOT SEAT

As an industry leader, Hall Longmore constantly tracks market trends in our sectors and through technological innovation, capacity expansion, and an ongoing investment in personnel we are continuously improving on our products, processes and strategies.”

Mmatsheko Shai, Sales & Marketing Executive, Hall Longmore I S S N 0 2 5 7 19 7 8 Vo l u m e 5 0 N o . 0 6 • J u l y 2 0 2 5 • R 5 5 . 0 0 ( i n c l . VAT )

INSIDE

VOLUME 50 NO. 06 JULY 2025

37 Regulars

www.imesa.org.za www.imesa.org.za

IMESA The official magazine of the Institute of Municipal Engineering of Southern Africa

Editor’s comment President’s comment Index to advertisers

3 5 48

INFRASTRUCTURE DEVELOPMENT • SERVICE DELIVERY • ROADS • BUILDING • MAINTENANCE • ENERGY • WASTE

INDUSTRY INSIGHT

BITUMEN & ASPHALT

SAT: A new era of excellence

Peter Telle

CEO of Ultra Control Valves

Harnessing the energy of water to optimise valve performance

INFORMATION & COMMUNICATIONS TECHNOLOGY

The transformative nexus of AI, BIM, and digital twinning

RESERVOIRS

Innovative developments in precast water storage

Cover Story CFAO takes material handling to the next level

takes material handling to the next level

30

Concor progresses on Karreebosch Wind Farm

34

Consulting Engineers 9

Royal HaskoningDHV South Africa becomes Atana

35

Industry Insight IN THE HOT SEAT

As an industry leader, Hall Longmore constantly tracks market trends in our sectors and through technological innovation, capacity expansion, and an ongoing investment in personnel we are continuously improving on our products, processes and strategies.”

Mmatsheko Shai, Sales & Marketing Executive, Hall Longmore I S S N 0 2 5 7 19 7 8 Vo l u m e 5 0 N o . 0 6 • J u l y 2 0 2 5 • R 5 5 . 0 0 ( i n c l . VAT )

ON THE COVER Backed by its turnkey services and best-in-class brands, CFAO Equipment fields a comprehensive range of new and preowned material handling solutions to meet a broad range of industry requirements.

This includes a growing demand for electric powered machines that help to lower operating costs and carbon footprints. P6

IN THE HOT SEAT Spearheading innovation and manufacturing excellence for more than 10 decades, Hall Longmore is invested and committed to supporting South Africa’s industrial and infrastructure development. IMIESA speaks to Mmatsheko Shai, Hall Longmore’s Sales & Marketing Executive, about the company’s evolving mission to deliver enduring value for enterprises and society. P12

43

Resin injection counters stormwater induced subsidence

Renewable Energy & Electrification 6

IMESA Empowering the next generation.

Join the IMESA Young Professionals Portfolio (YP²)

Geotechnical & Environmental Engineering

VEHICLES & EQUIPMENT

Hydraulic power generation.

Harnessing the energy of water to optimise valve performance

Water & Wastewater 10

Hot Seat Gearing up for the next 100 years in steel pipe leadership

12

Sustainability Water conservation strategies for sustainable construction The evolution of carbon dioxide removal technologies

39

Bitumen & Asphalt SAT: A new era of excellence

40

Vehicles & Equipment Ngquza Hill Municipality turns to Bell to boost its fleet

43

A case study in 3D engineering and heavy lifting

44

22

Cement & Concrete

26

Legal

PERMEABLE PAVING

38

High-pressure jetting and vacuum trucks: hydraulic versus v-belt pumps

Information & Communications Technology

48

37

Cut construction costs with alternative water solutions

15

Reservoirs

Construction and infrastructure disputes. Forensic expertise strengthens legal outcomes

Cape Flats water plant wins top architecture award

Pump Systems

SAPPMA reinforces commitment to quality amid growing industry concerns 16 Jacques van Eck appointed as SAPPMA quality manager 17 Engineering standards in water infrastructure: A call for evidence-based design practices 18

Elevating the built environment. The transformative nexus of AI, BIM, and digital twinning

36

14

Pipelines: Bulk & Reticulation

Corestruc constructs solid foundations in the water infrastructure market

Xylem Africa wins gold for safety at the RoSPA Awards 2024

AfriSam builds contractor success with more than just cement

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Producing sustainable concrete without construction delays

47

Permeable Paving 29

Eco-friendly Terracrete pavers help preserve Ningaloo coastal zone

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INDUSTRY INSIGHT Control valves play an essential role in optimising pipeline water pressure and can either be regulated manually or via automated control, which then requires a constant power source. IMIESA speaks to Peter Telle, CEO of Ultra Control Valves, about their hydraulic power generator solution. P10

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EDITOR’S COMMENT EDITOR Alastair Currie Email: alastair@infraprojects.co.za DESIGNER Beren Bauermeister CONTRIBUTORS Devesh Mothilall, Dhiveshni Naidu, Eve Pope, Geoff Tooley, Ian Venter, Roxanne Canny DISTRIBUTION MANAGER Nomsa Masina DISTRIBUTION COORDINATOR Asha Pursotham SUBSCRIPTIONS Email: distribution@infraprojects.co.za ____________________________________________ ADVERTISING SALES KEY ACCOUNT MANAGER Joanne Lawrie Tel: +27 (0)82 346 5338 Email: joanne@infraprojects.co.za ____________________________________________

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ANNUAL SUBSCRIPTION: R805.00 (INCL VAT) ISSN 0257 1978 IMIESA, Inst.MUNIC. ENG. S. AFR. © Copyright 2025. All rights reserved. ____________________________________________ IMESA CONTACTS HEAD OFFICE: Manager: Ingrid Botton P.O. Box 2190, Westville, 3630 Tel: +27 (0)31 266 3263 Email: admin@imesa.org.za Website: www.imesa.org.za BORDER Secretary: Celeste Vosloo Tel: +27 (0)43 705 2433 Email: celestev@buffalocity.gov.za EASTERN CAPE Secretary: Susan Canestra Tel: +27 (0)41 585 4142 ext. 7 Email: imesaec@imesa.org.za KWAZULU-NATAL Secretary: Narisha Sogan Tel: +27 (0)31 266 3263 Email: imesakzn@imesa.org.za NORTHERN PROVINCES Secretary: Lethale Magagane Tel: +27 (0)72 059 7444 Email: np@imesa.org.za SOUTHERN CAPE KAROO Secretary: Henrietta Oliver Tel: +27 (0)79 390 7536 Email: imesasck@imesa.org.za WESTERN CAPE Secretary: Michelle Ackerman Tel: +27 (0)21 444 7112 Email: imesawc@imesa.org.za FREE STATE & NORTHERN CAPE Secretary: Wilma Van Der Walt Tel: +27 (0)83 457 4362 Email: imesafsnc@imesa.org.za All material herein IMIESA is copyright protected and may not be reproduced without the prior written permission of the publisher. The views of the authors do not necessarily reflect those of the Institute of Municipal Engineering of Southern Africa or the publishers.

Funded and self-funded public projects that build success

W

ith the new municipal financial year under way, effective 1st July 2025, there are high expectations from the South African construction sector that 2025/2026 will be a positive turning point for the industry.

Going forward, proactive and coherent public sector investment has now reached a crucial point in tackling the mounting infrastructure delivery backlog. For national government, it’s a fine balance in ensuring that international loans translate into measurable outcomes.

One of the latest cash injections is the recent US$1.5 billion Development Policy Loan Agreement concluded between the South African government and the World Bank. The key purpose of this ring-fenced loan is to support structural reforms that enable enhanced infrastructure services in key areas. These include the energy and freight transport sectors.

Operation Vulindlela This financing arrangement also aligns with Operation Vulindlela – a joint initiative of the Presidency and National Treasury – with Phase I launched in 2020. Phase II, which commenced in March 2025, continues to build on the initial five priority reform areas to enable rapid, inclusive, and sustained economic growth. There are now seven for Phase II covering energy, water, freight logistics, the visa system, local government, spatial integration and housing, and digital public infrastructure.

The first Operation Vulindlela Phase II progress report released for 2025/2026 celebrates a number of key milestones that underscore meaningful traction. On the energy front, these include NERSA’s approval of the National Wheeling Framework on 3rd March 2025. The draft Electricity Transmission Infrastructure Regulations, which closed for public comment in May 2025, now also brings the market a step closer to the first phase of Independent Transmission Projects.

Within the freight segment, progress is being made to facilitate private sector participation in port and rail logistics, with the launch of a request for proposals in the pipeline for 2025.

Meanwhile, Operation Vulindlela’s National Water Action Plan continues to unfold, working in conjunction with the Department of Water and Sanitation (DWS), alongside a series of other initiatives that encompass non-revenue water reduction programmes across metros.

At grassroots level, one of the most crucial reform areas remains local government, where financial sustainability is the foundation for future turnaround per formance.

Proactive examples include the submission of Performance Improvement Action Plans by specific metros to stabilise and strengthen their electricity and water utilities. The billions owed to Eskom and Water Boards are the two crucial areas that need attention. Another is the need to revisit municipal electricity tariffs that are becoming increasingly unaffordable.

Adopting off-grid renewable interventions like solar PV is a luxury many can’t afford, which is why equitable wheeling and independent power producer arrangements are a logical progression. Managed intelligently, it’s a win-win for municipalities and their constituents in terms of affordable power tariffs and a degree of outsourced infrastructure investment.

Rather than relying on water and electricity as major revenue sources, the obvious supplementary route to follow is an enabling investment environment that boosts commercial and property development. While not the largest contributor, property rates still contribute a sizeable proportion of municipal income streams, of which a percentage is used to fund new build and maintenance projects.

Importance of property ownership The provision of water and sanitation services is a basic human right, but so too should be property ownership.

Operation Vulindlela Phase II acknowledges this need.

Examples include ensuring that title deeds are correctly registered for current RDP householders; making provision for affordable housing finance; and developing a demandside subsidy programme for affordable rental housing.

Successful public-private partnerships continue to drive the change we need to see within this landscape.

Overall though, what South Africa needs is a major shift from a planning to a “construction under way” status. The most essential component in the equation is a professionally equipped public service in terms of administration, finance and built environment proficiency. The ingredients for success are all there.

Alastair

To our avid readers, check out what we are talking about on our website, Facebook page or follow us on Twitter and have your say. www.imesa.org.za

IMESA

IMESA

imesa_za

imesa

www.imesa.org.za

The official magazine of the Institute of Municipal Engineering of Southern Africa

INFRASTRUCTURE DEVELOPMENT • SERVICE DELIVERY • ROADS • BUILDING • MAINTENANCE • ENERGY • WASTE

INDUSTRY INSIGHT

BITUMEN & ASPHALT

SAT: A new era of excellence

Peter Telle

CEO of Ultra Control Valves

Harnessing the energy of water to optimise valve performance

INFORMATION & COMMUNICATIONS TECHNOLOGY

The transformative nexus of AI, BIM, and digital twinning

RESERVOIRS

Innovative developments in precast water storage

The ABC logo is a valued stamp of measurement and trust. IMIESA is ABC audited and certified.

Local government revenue streams

takes material handling to the next level

Cover opportunity In each issue, IMIESA offers advertisers the opportunity to get to the front of the line by placing a company, product or service on the front cover of the journal. Buying this position will afford the advertiser the cover story and maximum exposure. For more information on cover bookings, contact Joanne Lawrie on +27 (0)82 346 5338.

IN THE HOT SEAT

As an industry leader, Hall Longmore constantly tracks market trends in our sectors and through technological innovation, capacity expansion, and an ongoing investment in personnel we are continuously improving on our products, processes and strategies.”

Mmatsheko Shai, Sales & Marketing Executive, Hall Longmore I S S N 0 2 5 7 19 7 8 Vo l u m e 5 0 N o . 0 6 • J u l y 2 0 2 5 • R 5 5 . 0 0 ( i n c l . VAT )

IMIESA July 2025

3

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PRESIDENT’S COMMENT

IMESA

Engineers must be included in all infrastructure approvals One of the key challenges that impacts on effective infrastructure delivery at local government level is that municipal tender evaluation committees (TECs) tend to be dominated by non-technical decision-makers. The same is frequently true for bid adjudication committees (BACs) responsible for approving tenders based on correct contractual procedures.

T

his is a key issue that IMESA has constantly red flagged and it’s one that urgently needs addressing. There are two key reasons. Firstly, there’s an unacceptably high number of contractors being awarded work that they are not competently equipped to complete, often based on lowest cost.

That then creates a potential ethical conflict for municipal engineers registered with the Engineering Council of South Africa (ECSA) in terms of the Engineering Profession Act 46 of 2000. ECSA establishes strict codes of conduct and penalties for misconduct, reinforcing the need for world-class design risk assessment and verification.

Therefore, registered engineers must serve on both TECs and BACs as both an ethical and legal requirement. The fact that they often don’t has no plausible argument, and the downstream implications of continuing this practice are well reflected by past Auditor-General South Africa (AGSA) repor ts on local government audit outcomes.

For the 2023/2024 period, key AGSA findings within flagged municipalities included project delays, poor quality construction work, and cost overruns. Lack of due diligence processes in appointing contractors with a proven track record for the work awarded was cited as a common issue.

This underscores the essential role that municipal engineers play in vetting contractor competency prior to the TEC process. That includes a material assessment to determine if the project value covers the minimum construction costs put forward by the bidder.

We do this as a standard protocol, which then goes into the engineer’s report submitted to the BEC, along with a declined or approved recommendation. What happens from there is currently outside our control and needs to be challenged, especially when decline recommendations are ignored.

commercial, and industrial developments within the context of rapid population growth and intensified urbanisation.

Obviously, that’s infrastructure dependent in terms of existing and future municipal services implementation for brownfield and greenfield projects. Along with key elements like water and wastewater, this includes modelling for increased traffic management accommodation.

Each municipality in South Africa has its own bylaws that determine allowable coverage limits within its Town Planning Scheme in line with Spatial Planning and Land Use Management Act (SPLUMA) stipulations.

Coverage is defined as a set percentage of the maximum allowable building footprint on a sur veyed property, which can range from 30 to 60%, or higher. In other words, if an ERF measures 1 000 m2, and the coverage limit is set at 40%, then buildings can only occupy 400 m2 of the available space. There’s also a permissible degree of hardened areas allowed, like impermeable paving.

The rationale includes controlling hard surface run-off to optimise stormwater management, thereby creating a healthy balance between grey and green infrastructure. It’s meant to be a proactive way of achieving a sustainable degree of densification.

For example, increasing the allowable coverage of an existing developed site from 30% to 40% can increase the stormwater run-off by approximately 17%. When you multiply the impact of other neighbouring allied developments within this range, that increases the load on current stormwater systems exponentially. They may then be unable to cope with subsequent storm events, resulting in infrastructure and property damage due to flooding.

Coverage flexibility Coverage limits Communication and alignment between engineers and other built environment professionals are equally vital. A case in point is the town planning profession. They are instrumental in devising urban, peri-urban, and rural models for residential,

Since each town and city has its own unique requirements, the ideal is to achieve a degree of coverage limit flexibility, case by case – subject to

official zoning approvals – rather than imposing a blanket percentage that, being too rigid, impedes viable development opportunities.

An example could include a waste-to-energy plant proposal within an established urban area that requires a 70% coverage in a zoned 30% area.

Where there’s a clear socio-economic benefit, that would justify the motivation for additional investments in municipal electricity, water, and sewage connections.

Plus, global arguments underscore the advantages of multi-storey buildings that meet footprint goals without compromising on green spaces. This is determined by a zoning tool known as Floor Area Ratio (FAR) that regulates occupancy limits.

Going multilevel doesn’t reduce the water and wastewater load. However, it does make a resounding business case for optimum coverage when intelligently designed and located close to work and allied amenities. There are also major opportunities to revitalise central business districts, converting dormant and abandoned buildings into viable mixed-use developments, where the bulk of the underground service infrastructure is already in place.

Professional collaboration Civil engineers are professionally equipped to understand what works best in practice. This includes accurate funding determinations for construction and maintenance budget approvals.

That in turn has a positive spin-off for town planners and municipal authority decision-makers in allowing engineers, builders, and architects to achieve positive sustainability outcomes as an integrated professional par tnership. Foremost though, all infrastructure projects must involve municipal engineering input from the onset.

Geoff Tooley, Pr Eng Hon FIMESA, IMESA President: 2024-2026

IMIESA July 2025

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COVER STORY

The Konecranes E-VER forklift has a fully electric driveline, reducing energy consumption by up to 70% when compared to conventional diesel-powered units

CFAO takes material handling to the next level Backed by its turnkey ser vices and best-in-class brands, CFAO Equipment fields a comprehensive range of new and preowned material handling solutions to meet a broad range of industr y requirements. This includes a growing demand for electric powered machines that help to lower operating costs and carbon footprints.

Sonia Pretorius, National Sales Manager for CFAO Equipment’s 600SA division

I

n parallel with its counterbalance line, one of the fastest growing segments globally and in South Africa is the truckmounted crane market, with all industries recognising their durability, versatility and ability to operate in the toughest, most challenging environments.

“When 600SA, a division of CFAO Equipment, secured the exclusive distributorship of the

Lenny Naidoo, National Product Specialist for CFAO Equipment’s Heavy Lift division

COVER STORY

PESCI® COPMA® range of truck-mounted cranes for South Africa and Sub-Saharan Africa late last year, it was a strategic response to a growing customer need and a commitment to enhancing its crane of ferings,” explains Sonia Pretorius, National Sales Manager for 600SA. “This has been a real game-changer for customers because these units provide a high degree of unrivalled application flexibility.”

In addition to lifting and transpor ting, PESCI® COPMA® cranes can be equipped with secondary booms, jibs, remote controls and work platforms for a host of applications.

Sectors range from mining, construction, logistics and municipal infrastructure projects to road utility services, agriculture and rigging.

“Ever wondered how heavy materials, products and machinery are lifted into highrise buildings? It’s done using cranes with a reach of 15 to 27 m, or more if a jib is added,” explains Pretorius. “Choosing the right PESCI® COPMA® crane for each specific task involves considering multiple technical factors, but the adaptability of these units ensures they can handle any job.”

Pretorius highlights that a key benefit to owning a PESCI® COPMA® crane is its knuckle-boom feature, which provides increased flexibility in confined spaces or when lifting loads close to the truck, making it more versatile than other cranes available on the market.

Some other top reasons to invest in this versatile equipment include: • Streamlined operations: Truck-mounted cranes integrate transpor tation and lifting, allowing loads to be moved from one location to another without the need to arrange separate lifting equipment at both ends. Truck-mounted cranes are also ideal for jobs in remote locations that lack access to standard lifting equipment, offering a true end-to-end solution.

• Quick setup, fast results: Whether lifting, loading or offloading, the setup is fast, and the results are immediate. Time is money, and truck-mounted cranes deliver efficiency. With simple, quick deployment, these cranes reduce downtime and speed up project timelines.

• Incredible versatility: Perhaps one of the greatest advantages of truck-mounted cranes is their ability to handle multiple tasks.

• O n-demand convenience: Owners can deploy the crane whenever they need to,

avoiding delays. Whether Included in these calculations PESCI® COPMA® truck-mounted it’s to fell a tree, lift a are axle loads, centre of cranes can be equipped heavy piece of concrete gravity and the structural with secondary booms, or move a container, impact on the truck chassis,” jibs, remote controls and work platforms she continues. operators can get it for a host of done immediately.

To ensure the equipment applications Ultimately, investing in is used safely and effectively, 600SA also provides comprehensive truck-mounted cranes offers operator training on crane operations, load businesses the oppor tunity to balancing and safety protocols. “It’s a smart tackle a broader range of projects and scale up operations. “With this equipment, investment that brings long-term value to any businesses can easily take on larger jobs operation,” adds Pretorius. or rent them out to other operations for additional revenue. This leads to a significant Empty container handlers go electric competitive advantage in the marketplace,” At CFAO Equipment, there’s a solution for notes Pretorius. every niche. A prime example is the ports 600SA offers a pre-purchase consultation and container depot market, which is one to assess which crane is best suited to a of the most demanding environments for particular operation. “After this, we assess counterbalance machines. It’s also a critical the truck used and calculate truck-to-crane area for ensuring that imports and exports stability to ensure safety when lifting loads. reach their destination in the shor test

IMIESA July 2025

7

COVER STORY

time possible through enhanced terminal efficiencies.

“For both private and public customers, there’s an increasing requirement to transition from diesel to electric equipment without compromising on efficiencies,” says Lenny Naidoo, National Product Specialist for CFAO Equipment’s Heavy Lift division.

“In response, CFAO Equipment has introduced the Konecranes E-ACE electric empty container handler. In addition to generating zero emissions, the E-ACE lifts up to 21% faster and handles slopes with up to an 18% greater acceleration rate than its diesel alternative,” Naidoo explains.

These electric empty container handlers, which have a lifting capacity of between 8 and 11 tons at around 1.2 m, are as robust as their diesel counterpar ts. “Not only are they more eco-friendly, but they offer immediate power on demand, making them true examples of power in motion.”

Fur thermore, the E-ACE consumes less energy due to its modern high voltage technology, which allows for six to 12 hours

Konecranes’ E-ACE electric empty container handler lifts up to 21% faster and handles slopes with up to an 18% greater acceleration rate than its diesel counterparts

of operation without charging. Additionally, there are flexible charging options, using either 282 kW or 350 kW lithium-ion batteries, which can be fully charged in one hour using GB/T or CCS dual port charging.

Naidoo says operations that invest in electric empty container handlers will need to install a charging por t facility. “Reefer container depots will have less to do because the reefer containers require high voltage electricity, so the infrastructure is already in place.”

Overall, the decreased power consumption, combined with a lack of tailpipe emissions, mean a significantly reduced CO2 footprint, ensuring that users get closer to achieving their sustainability goals when investing in an E-ACE. Notably, drivers experience up to 50% less noise and vibrations during operation and no vibrations during idling. “This is because the diesel configuration that created the noise and vibrations has been replaced with electric components,” explains Naidoo.

Ergonomically, the E-ACE offers one of the

safest, most spacious and quietest cabins in the industry – the OPTIMA cabin – which provides exceptional visibility in all directions.

E-VER electric forklift Another key addition in the Konecranes lineup for South Africa is the E-VER all electric forklift range, with the latest generation launched globally in Q4 2024. Depending on the model, lifting capacities range from 10 to 25 tons.

These workhorses are suitable for all heavy-duty industrial applications and – like the E-ACE – are equipped with a lithium-ion battery that powers highly efficient electric motors for traction and hydraulics. Following the common CCS1 and CCS2 standards, battery charging can take less than an hour, plus there are top-ups from braking energy during busy work shifts.

“The E-VER is the epitome of sustainable and eco-friendly equipment. Its optimised weight distribution enables smooth, reliable operation and easy manoeuvrability.

Additionally, its powerful motors lift fast and accelerate quickly, even when fully loaded on a slope,” says Naidoo.

“There’s no doubt that e-machines are the future. When electricity rates are stable, charging an electric forklift is generally more affordable than refuelling with diesel,” he adds. “Plus, with fewer moving parts, electric forklifts require less maintenance.”

The right balance The upfront cost of material handling is a critical consideration, which comes down to the right machine selection. It’s all about enhancing productivity – safely and effectively.

“At CFAO Equipment, we are committed to facilitating customer success. That hinges on enabling par tnerships through tailored solutions that add enduring value. Our track record since our foundation in 1984 reinforces this value proposition,” Pretorius concludes.

www.cfaoequipment.co.za

8 IMIESA July 2025

IMESA

EMPOWERING THE NEXT GENERATION THE IMESA KWAZULU-NATAL YP2 COMMITTEE From left to right, starting with the back row: Nkanyezi Mdlalose, Dhiresh Dhewki, Lenesh Sukhlal, Roxanne Canny, Zlungile Mamela, Ntokozo Mjwara and Dhiveshni Naidu

Sur vival Centre and Crèche, reflecting their dedication to social responsibility.

Roadmap for balance of 2025 and going into 2026

Join the IMESA Young Professionals Portfolio (YP²) The IMESA Young Professionals Portfolio (YP²) is a vibrant and growing initiative committed to nurturing young talent in the municipal engineering sector.

By Roxanne Canny, Pr Eng* and Dhiveshni Naidu, Pr Eng**

W

ith a clear focus on bridging the gap between knowledge, experience, and opportunity, YP² equips early career professionals with the tools to thrive through mentorship, training, and exposure to real-world challenges.

Initially launched within the KwaZulu-Natal (KZN) branch, YP² has gained universal recognition in industry for its instrumental role, with IMESA Past President, Bhavna Soni, now driving a national rollout campaign at EXCO level. The objective is to extend YP²’s reach across South Africa, ensuring that young professionals in every province benefit.

This evolution enables wider access to structured development platforms and encourages collaboration across branches. In 2026 our goal is to ensure that every branch has YP² representation.

Future ready and creative with innovative events YP²’s mandate is grounded in building future ready engineers by promoting both technical competence and leadership development.

Through continuous professional development (CPD) accredited workshops, engaging events, and active community involvement, YP² fosters a professional culture where learning, growth, and innovation are at the forefront.

Since its inception, YP² KZN has delivered several impactful initiatives. These include our version of the Amazing Race. In 2024 our Engineers’ Edition put problem-solving and team building front and centre. It was a massive success and a definite repeat event in KZN, as well as countrywide in 2026.

Turning back to 2024, and in collaboration with the South African Institution of Civil Engineering (SAICE), YP² launched a successful Calculator Drive to suppor t under-resourced students.

Additionally, we also enhanced visibility through creative campaigns at events like the IMESA KZN Golf Day. YP² members have also played leading roles in planning high profile events like the annual KZN Women’s Day Breakfast and Golf Day, promoting the role and value of women in engineering.

The YP² KZN committee also led a 2024 Christmas Drive to suppor t the Children’s

Looking ahead, the remainder of 2025 and early 2026 presents an ambitious and inspiring roadmap. Foremost, Mandela Day, celebrated annually on 18th July each year, is always a major YP² KZN event. This year we focused our participation on eThekwini’s Mandela Day Beach Clean-Up. The day before, we held a roadshow at Varsity College in Durban aimed at introducing students to the municipal engineering profession, thereby strengthening the pipeline of future engineers.

Going forward, September 2025 will see the roll-out of a CPD-accredited KZN YP² leadership workshop, while technical Quiz Nights and a planned social sports event will close off the year with fun and inclusive networking.

Plans for 2026 include a mini conference and the launch of an exciting initiative, “Who wants to be an engineer?”, designed to engage high school learners in engineering careers.

As part of its forward strategy, YP² also aims to deepen engagement with private sector stakeholders and expand school outreach initiatives – further aligning education pathways with industry needs.

Membership growth Membership continues to grow, reflecting a strong appetite among young professionals for structured development, meaningful involvement, and leadership opportunities. What began as a small, passionate group in KZN has evolved into a national movement of emerging engineers eager to make their mark.

With continued IMESA EXCO suppor t, YP² is poised to deepen its impact, strengthen inter-branch collaboration, and shape a more inclusive and resilient engineering profession for South Africa.

For further information, visit www.imesa.org.za *Branch Chair, IMESA KwaZulu-Natal YP 2 **IMESA KwaZulu-Natal YP 2 Committee Member

IMIESA July 2025

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INDUSTRY INSIGHT | PRESSURE MANAGEMENT

HYDRAULIC POWER GENERATION

Harnessing the energy of water to optimise valve performance Control valves play an essential role in optimising pipeline water pressure and can either be regulated manually or via automated control, which then requires a constant power source. For actuated valves, which require external power, this presents a challenge when electricity outages occur, leading to knock-on effects that include water hammer and pipe bursts. IMIESA speaks to Peter Telle, CEO of Ultra Control Valves, about their hydraulic power generator solution.

E

ssentially there are three different types of pressure reducing valves (PRVs), comprising direct acting valves, pilot operated pressure reducing valves (POPRVs), and ratio reducing pressure valves (RRPVs). Their purpose is to automatically maintain constant pressure by eliminating flow fluctuations.

Direct acting valves are very simple devices with an adjustable handle to set the pressure to the required value, while POPRVs are commonly used for large systems. In turn, RRPVs reduce pressure in a ratio between upstream and downstream pressure and have a fixed setting.

“POPRVs are the most sophisticated and incorporate pilot mounted electronic fittings Peter Telle, CEO of Ultra Control Valves, with the Ultra Alpine Pressure Management solution for POPRVs

10 IMIESA July 2025

that enable smart control via sensors to meet requirements that include fluctuating water demand, as well as to counter technical losses due to pipeline leakages,” explains Telle.

“Remote operation is enabled via our Ultra Alpine Pressure Management cloudbased solution to achieve either time or flow modulated pressure management.

Troubleshooting benefits include real-time alerts of valve malfunction, which for POPRVs is often in the open position when a control circuit fault occurs. It’s a self-contained system with no external power required, since the pilot system is commonly battery powered. But what if the battery runs flat?”

Maric flow control valves keep pumps running on their efficiency curve irrespective of pressures or demands. This is also a great device for water saving

Kinetic benefits Telle argues that an alternative and more failsafe solution is to harness the kinetic energy produced by water flows within the pipeline to produce electricity, a common practice worldwide but relatively new for South Africa.

Typically, these Alpine Flow Control (AFC) mini generators are fitted across the inlet and outlet ports of the control valve, with power generated via existing mains pressure. For the hydraulic power generator to work, a pressure drop needs to occur, with a minimum 0,5 bar pressure differential (delta P) required. During operation, water flows rotate a series of blades on the generator’s rotor shaft, converting the mechanical (kinetic) energy into electrical energy at 24 W under 1 bar, and 15 W under 0,5 bar.

The turbine speed is controlled using a differential control pilot, which constantly adjusts the flow rate and pressure differentials within the hydraulic system. Furthermore, the inclusion of ceramic bearings ensures trouble free per formance and reduces the need for frequent maintenance or replacements.

Additionally, AFC’s hydraulic power generators

INDUSTRY INSIGHT | PRESSURE MANAGEMENT

“So, we believe our generator solution is a real gamechanger, and especially ideal for rural infrastructure, like reservoirs. Here the generator will power the isolating valve, as well as any telemetry employed to monitor levels and valve performance.”

The system is suitable for all valves sizes at maximum working pressures of between 10 and 40 bar.

Ultra ACV RRPVs are available in sizes from 25 mm to 500 mm and pressure ratings up to 150 bar

do not have moving seals in the turbine.

This eliminates the risk of water contact with electrical components.

Power options for POPRVs and actuated valves The two key solutions being fielded by Ultra Control Valves comprise AFC’s MPGX – a smaller generator to keep the batteries charged on “smart” POPRV controllers; and a larger unit (the IHPG) designed to open or close any electrically actuated valve. Examples of the latter include butterfly and gate valves. Both can be operated manually but require power for remote control.

“Alongside pressure reducing valves, actuated valves perform critical functions that include opening, closing, and regulating flow and pressure within bulk water systems. This makes guaranteed power an essential requirement for optimum automation,” Telle explains.

For POPRVs, the generator charges batteries with voltages ranging from 12V to 24V DC for devices such as sensors, monitoring systems, and small-scale electronics. Three hours of charging will generate sufficient power to run a valve controller for a day.

“Using a hydraulic power generator offers a key advantage compared to alternatives, like solar panels, which are also battery power dependent and prone to theft. The option of putting in an electricity connection in more remote locations is also costly,” says Telle.

The Ultra Alpine ACV diaphragm operated control valve

Ultra’s pressure reducing valve line-up Ultra Control Valves supply three different types of pressure reducing control valves.

These comprise the Ultra Alpine ACV diaphragm operated control valve (a POPRV); the Ultra ACV RRPV, available in sizes from 25 mm to 500 mm and pressure ratings up to 150 bar; and the Maric flow control valve, designed to keep pumps on their optimum efficiency curve irrespective of pressures or demands.

Every control valve in industry has a particular pressure drop ratio that it’s able to handle without cavitation occurring. For most standard control valves this ratio is 3:1, i.e. if the incoming pressure is 9 bar the valve can comfortably handle an outlet pressure of 3 bar. However, most standard POPRVs with a maximum 3:1 capability would have to install two valves in series in the aforementioned pressure scenario.

“In contrast, our Ultra Alpine ACV valve can handle a 4:1 ratio, allowing the downstream pressure to be set at around 2.25 bar,” Telle explains, adding that the valve features V ports for cavitation prevention (if the pressure drop is higher than 4:1) and low flow control.

Another important consideration for control valve selection is night-time/off-peak demand.

All standard control valves have a minimum functional flow rate. If flows go below this value, the valve becomes unstable and could cause pipe breaks. To counter this scenario, a smaller valve normally needs to be installed in parallel to automatically handle low flow during night-time demand. The upside is that the Ultra Alpine ACV has special trims available to handle low flows without the need for bypass valves. Plus, a new device called a control stabiliser totally eliminates the need for a low flow bypass valve.

“We believe that one of the best mainstream options for water utilities is the RRPV due to its simplicity. It consists of a piston with different inlet and outlet areas. It doesn’t even look like a valve but a simple spool piece, and it performs exceptionally well and has been well proven in the South African mining industry for decades, with growing penetration into the local potable water market,” Telle asserts.

Key advantages of RRPVs include their tamper proof make-up; they can act in series without

The IHPG hydraulic power generator (above) is designed to supplement or replace grid supplied power, while the MPGX (right) has been developed for POPRVs. Both are manufactured using 316SS stainless steel and are IP68 compliant

instability; are inherently failure proof; and not vulnerable to dirt particles. Additionally, the axial flow path enables high pressure drops (up to 5:1).

The RRPV also has an immediate reaction time, unlike POPRVs, which have a delayed reaction time to demand changes. This can sometimes create problems in maintaining “dead-end” control of downstream pressures when there is no flow. However, when installed upstream, RRPVs react “instantaneously” to the position changes of the POPRV, with elimination of any instability issues.

“If POPRVs act in series, they must be carefully ‘tuned’ during commissioning. With the slightest disruption in demand or pressure, instability will occur. So, 24-hour monitoring is essential, which is where the Ultra Alpine Pressure Management cloud-based solution comes to the fore,” says Telle.

“Adding a hydraulic power generator provides an extra layer of system security, providing peace of mind for utility operators in the provision of uninterrupted water supply. The same is true for actuated valves in the field,” Telle concludes.

www.ultravalves.co.za IMIESA July 2025

11

HOT SEAT

GEARING UP FOR THE NEXT

100 YEARS

IN STEEL PIPE LEADERSHIP Spearheading innovation and manufacturing excellence for more than 10 decades, Hall Longmore is invested and committed to supporting South Africa’s industrial and infrastructure development. IMIESA speaks to Mmatsheko Shai, Hall Longmore’s Sales & Marketing Executive, about the company’s evolving mission to deliver enduring value for enterprises and society.

What attracted you to the steel pipe manufacturing industry?

The United Nations Sustainable Development Goal (SDG) 6 focuses on “Ensuring access to water and sanitation for all”. Hall Longmore aligns closely with this goal, and we believe that the bulk water infrastructure market will remain dominant until all South Africans have access to clean, running water supported by long-lasting, well-maintained infrastructure.

Hall Longmore manufactures steel pipes for a variety of sectors, including water, petrochemical, gas, mining and industrial applications. We celebrated our centennial in 2024, and with thousands of kilometres of pipeline produced since 1924, we proudly see

Mmatsheko Shai, Sales & Marketing Executive at Hall Longmore

12 IMIESA July 2025

ourselves as a critical stakeholder in the bulk water infrastructure value chain.

Personally, I was drawn to the impact and contribution of steel pipes in the construction of quality bulk water infrastructure, enabling access to safe and reliable water supply across South Africa and the continent.

In your view, where does Hall Longmore rank locally and globally as a market leader in the water, petrochemical, gas, mining, and industrial sectors?

As an industry leader, Hall Longmore constantly tracks market trends in our sectors and through technological innovation, capacity expansion, and an ongoing investment in personnel we are continuously improving on our products, processes and strategies.

Outside the water market, we manufacture “Oil Country Tubular Goods” (OCTG) pipes for the local and global petroleum and gas market. These pipes adhere to and often exceed the stringent American Petroleum Institute (API) standards.

Hall Longmore holds API licences for line pipe (API 5L, PSL 1 and PSL 2) and casing and tubing (API 5CT), placing us among a select group of manufacturers globally.

Through ongoing innovation, diversification, and investment, Hall Longmore brings world class manufacturing and quality assurance to

the South African market, supporting long-term infrastructure and industrial growth.

In addressing South Africa’s water infrastructure backlog, what are the key Hall Longmore product developments to fast-track construction and ensure optimum return on investment for asset owners?

To support efficient infrastructure development, Hall Longmore offers a variety of corrosion protection systems tailored to design and environmental requirements. These include our three-layer polyethylene system, and our proprietary Xtalene – a fusion bonded mediumdensity polyethylene (FBMDPE) coating for both buried and above ground applications.

Designed to accelerate construction, our Xtalene coated Rubber Ring Jointing (RRJ) system is a solution introduced to address some of the infrastructure backlogs while meeting the quality standard and longevity steel pipelines offer.

This system is particularly beneficial for bulk water infrastructure projects, allowing for a localised push-fit steel pipe application. The speed of installation and reduced labour costs associated with the RRJ system, combined with the long-term durability provided by the Xtalene coating, contribute to overall cost-effectiveness for asset owners.

HOT SEAT Hall Longmore’s Rubber Ring Joint 500 mm diameter pipe system is designed to streamline on-site connections

(QCTO). This guarantees quality training outcomes for our people – and quality products for our clients.

Does Hall Longmore provide community skills training and SMME contractor development programmes?

Hall Longmore’s Man of Steel logo reflects a proud history of innovation since the company’s formation in 1924.

In parallel, what steps are being taken to develop women in technical and leadership positions?

Hall Longmore is committed to inclusive growth, with a strong emphasis on youth and women empowerment through education, training, and development.

My own journey reflects this. I was awarded a bursary to study Industrial Engineering at Wits University, fully funded by the company. After gaining experience as a trainee and proving myself in a technical role, I advanced to Key Accounts Manager. Later, the company invested further in my development by sponsoring my MBA through Wits Business School. Today, as Sales & Marketing Executive, I continue to benefit from mentorship and leadership opportunities within the company.

Beyond my own experience, Hall Longmore prioritises continuous on-the-job training for our staff, ensuring that ever y employee has access to skills development. Additionally, Hall Longmore actively partners with impactful initiatives such as Yes4Youth and offers various learnerships programmes, deliberately creating entr y points for young women into the steel pipe manufacturing sector. This prepares such individuals to enter the employment market with gained knowledge and skills, meaningfully impacting their communities and contributing to the broader South African economy.

Several participants from these programmes have been permanently employed at Hall Longmore, with continued access to training via accredited providers, such as those recognised by the Quality Council for Trades and Occupations

Absolutely. Hall Longmore is committed to supporting community skills development and the growth of SMME contractors, particularly within the bulk infrastructure and construction sectors.

As part of this commitment, we offer practical, hands-on training focused on our RRJ system.

Held both on-site and at our facilities, this installation training is conducted by our technical and quality teams. Through this initiative, we empower contractors – especially emerging SMMEs – with the knowledge and exper tise needed to meet industry standards and execute successful projects.

Which R&D developments have been the most significant in Hall Longmore’s history to date?

As I mark 10 years at Hall Longmore, one standout achievement that reflects both our innovation and our national impact is the localisation of the fusion bonded medium-density polyethylene (FBMDPE) coating system, our proprietary Xtalene, which has been developed in partnership with the CSIR, Sasol, and Xuba.

This project represents a major R&D milestone in South Africa’s industrial journey: transitioning from imported coatings to a locally manufactured, high-per formance solution that aligns with government’s localisation targets.

More than a technical breakthrough, it has enabled us to roll out our push-fit RRJ steel pipe system, reducing installation time and labour while enhancing corrosion protection and sealing per formance. This system is now making it faster and more efficient to deliver critical water infrastructure across the country.

Another key R&D focus – and one we’ve actively championed – is our Fusion Bonded Epoxy (FBE).

A section of the Wadeville production line

Pipes manufactured and supplied for Rand Water expansion projects

While FBE is widely used in North America as a standalone system – particularly for above ground pipelines – it is relatively new to the South African market.

We launched an internal campaign to educate specifiers, engineers, and end-users on the benefits of FBE. As a result, we've seen growing acceptance of FBE coatings, par ticularly in the mining sector, where clients are seeking durable, chemically resistant coating systems for aggressive operating environments.

Together, these developments in Xtalene and FBE technologies reflect Hall Longmore’s commitment to pioneering fit-for-purpose coating systems that meet both international standards and the evolving needs of our local infrastructure sectors.

Is Hall Longmore ready for the upturn in South African construction?

Hall Longmore is fully prepared and eager for the anticipated upturn in the South African construction sector. We are excited by the volume and scale of infrastructure projects currently out on tender, as well as the government’s recently announced commitment to invest R156.3 billion in water and sanitation infrastructure development over the medium term.

As a key player in the steel pipe manufacturing industr y, we have strategically positioned ourselves to suppor t this growth – through robust manufacturing capacity, a skilled technical team, and a strong focus on quality and delivery performance. Our track record in supplying pipes for large-scale water, sanitation, and energy projects uniquely equips us to meet the demands of this new wave of infrastructure investment.

We look forward to playing a meaningful role in building South Africa’s future and contributing to sustainable economic development through our products, partnerships, and local empowerment efforts.

www.hall-longmore.co.za

IMIESA July 2025

13

SUSTAINABILIT Y

WATER CONSERVATION STRATEGIES FOR SUSTAINABLE CONSTRUCTION In South Africa, water is scarce, making it essential to develop smart water habits now.

W

ater, a resource that has been readily available for use by us, and long misunderstood to be plentiful, has in recent times outlined just how scarce a resource it is, particularly in our day-to-day activities, under climate change.

Water utilities face mounting pressure due to diverse climatic conditions such as droughts and flooding events. Added to this, the No Drop report has also indicated that water losses account for 40.8%, or 1.79 million m³. We lose most of our water due to issues like burst pipes, overflowing reservoirs, leaking connections, and inadequate or non-existent metering, which is a sign of the state of the water system. This underscores the vital importance of implementing water conservation strategies to encourage water efficiency in the world of construction.

Permeable pavements are an effective stormwater control measure and facilitate groundwater recharge.

(Photo credit: LID Permeable Paving)

Smart tips for water-wise construction practices

According to Global Data, the South African construction market is expected to increase at an average annual rate of more than 3% from 2024 to 2027. This increase is attributed to investments in transportation, energy, industrial and housing developments. This expansion directly impacts water consumption, as construction is a water intensive industry.

The significant water footprint is in connection to construction activities, starting from site preparation, concrete mixing, equipment cooling, and post-construction tasks, including plumbing to landscaping. As construction projects grow, so does the need for water, emphasising the importance of sustainable water management strategies in the industry.

• Use alternative water sources: To alleviate the pressure on potable water, construction sites can utilise rainwater, greywater, and reclaimed water for non-potable purposes such as equipment washing and dust suppression.

• A dopt efficient technologies: Without sacrificing on quality, water consumption can be decreased by incorporating a closed loop water recycling system. High-pressure, lowvolume washers, and water-efficient concrete mixing technologies can also be incorporated into operations.

• Design and plan for water efficiency: Water efficient building design is a fundamental component of sustainable construction.

Include water saving elements in building plans, such as rain gardens, water retention systems (reduce run-off), and permeable pavements (recharge groundwater). These characteristics efficiently manage stormwater in addition to conserving water.

To alleviate the pressure on potable water, construction sites can utilise rainwater, greywater, and reclaimed water for non-potable purposes. (Photo credit: JP Property Fund)

A leaking tap dripping once per second can waste over 11 000 litres (approximately 73 bathtubs to the brim) of water annually. (Photo credit: J&G Plumbing Solutions Doncaster East)

Why water conservation is vital in construction

High-pressure, low-volume washers help to lower on-site water consumption. (Photo credit: S&K Building Services)

• Plan landscaping wisely: Post-construction landscaping should include hydrozoning, where plants are irrigated according to their specific water needs, reducing water waste. Installing drip irrigation also ensures efficient water use.

• Prevent water loss through leak management: A leaking tap dripping once per second can waste over 11 000 litres (approximately 73 bathtubs to the brim) of water annually.

Thus, regular maintenance and inspection of plumbing, fixtures, and irrigation systems are essential to prevent water waste.

• Educate and train workers: Empower contract workers on the team with water conservation practices through awareness campaigns and promote an accountable culture. Simple practices, such as turning off the water while not in use, can result in large financial savings.

Embracing water conservation during construction is more than just a responsible choice – it’s a strategic one. Reduced water usage lowers project costs, minimises delays caused by water shortages, and aligns with global calls for sustainable development.

Always Be #WaterWise www.randwater.co.za 0860 10 10 60

SUSTAINABILITY

THE EVOLUTION OF CARBON DIOXIDE REMOVAL TECHNOLOGIES The popularity of carbon dioxide removal credits continues to rise, supported by initiatives such as the EU Emissions Trading System, plus evolving technologies. Chief among them are biochar, direct air capture (DAC), and bioenergy with carbon capture and storage (BECCS) solutions – all capable of generating carbon credits that businesses can purchase to reduce Scope 1,2 and 3 emissions. By Eve Pope*

B

iochar is produced via pyrolysis of biomass, locking away carbon dioxide taken in by plants during photosynthesis. Carbon removal credits from biochar are already being delivered at a large scale, with players such as Exomad Green, Varaha, and Carboneers among the top sellers. However, the economic benefits of biochar extend beyond the sale of carbon credits. Biochar can also improve soil properties – enhancing their productivity and resilience, as well as reducing fertiliser demand.

In terms of durable, high-quality, carbon dioxide removals, biochar carbon credits are often the lowest-priced. Even so, many carbon credit buyers prefer to purchase a portfolio that encompasses a range of carbon dioxide removal solutions.

This is because different types of carbon credits have their own strengths and weaknesses. For example, biochar carbon removal credits may have some drawbacks relating to the duration of removals, additionality concerns, and limited ability to scale up.

DAC In turn, DAC involves chemical or physical methods of capturing CO2 directly from the atmosphere and locking it away geologically for thousands of years. Removals are highly verifiable, so buyers can have confidence in the high quality of these credits. However, this nascent technology requires specialised equipment and large amounts of energy, so remains expensive. For example, some DAC carbon removal credits sell for over US$1 000 per tonne of CO2.

Currently, the biggest sellers of DAC carbon credits include 1PointFive, Climeworks, Heirloom, and Holocene. Two of these companies – 1PointFive and Holocene – are owned by Occidental Petroleum and use liquid solvents. In contrast, Climeworks and Heirloom use a solid sorbent-based approach.

Direct air capture has significant scale-up potential. However, uncertainties remain. These include whether low-cost green energy sources will be readily available given rising competition from

data centres, and whether strong financial support for DAC in the US will survive considering the Trump-era of uncertainty for climate technologies.

While buyers are willing to pay a premium to foster promising DAC technologies for the time being, as demand for high-quality carbon removal credits outstrips supply, costs will need to decrease to ensure the success of DAC long-term.

BECCS Within the mix, BECCS is gaining increasing traction. This technology involves capturing CO2 from the flue gas of an industrial biogenic process – typically ethanol production or biomass combustion – hence the term “bioenergy”. Higher CO2 concentrations mean this process is less expensive than DAC but still has the same longduration, high-quality removals.

In recent months, there’s been a surge in interest for BECCS from the voluntary carbon credit markets. For example, Microsoft, the biggest corporate buyer of carbon dioxide removal credits, signed the largest carbon removal deal ever in April 2025 for ~7 million tonnes of BECCS credits. The deal, concluded with AtmosClear, was reportedly worth US$800 million. Further activity is expected as government backing emerges for BECCS, with the US, Denmark, and Sweden already providing significant support.

Other carbon dioxide removal technologies Beyond biochar, DAC, and BECCS, other carbon dioxide removal solutions can range from planting trees (afforestation/deforestation) to harnessing the power of the ocean via ocean alkalinity enhancement, direct ocean capture, and seaweed sinking.

Overall, whatever the solutions chosen, there’s a pressing need for increasing interventions.

The ultimate goal is to achieve global net zero greenhouse gas emission targets by 2050, in accordance with the Paris Agreement. To achieve this, billions of tonnes of carbon dioxide removal will be required annually.

In response, this will require many carbon dioxide removal technologies to scale up.

Additionally, increased support from businesses and governments alike needs to come sooner rather than later.

For fur ther reference, IDTechEx’s repor t entitled “Carbon Dioxide Removal (CDR) 2025-2035: Technologies, Players, Carbon Credit Markets, and Forecasts” provides an in-depth analysis of current trends. To find out more, including downloadable sample pages, visit www.IDTechEx.com/CDR. *Senior Technology Analyst, IDTechEx

IMIESA July 2025

15

PIPELINES – BULK & RETICULATION

SAPPMA reinforces commitment to quality amid growing industry concerns The ongoing battle against sub-standard plastic pipes and fittings remains a top priority for the Southern African Plastic Pipe Manufacturers Association (SAPPMA), as the prevalence of poor-quality products continues to threaten the integrity of the local industry.

R

ecent developments indicate that the problem is not abating.

In fact, it may be worsening.

However, SAPPMA believes that with a steadfast focus on quality by both the Association and its members, the industry’s decline can be halted and reversed.

During a recent members meeting, SAPPMA CEO Jan Venter reiterated the importance of

Jan Venter, CEO of SAPPMA

16 IMIESA July 2025

upholding the SAPPMA Code of Conduct, stressing that full compliance is key to minimising, if not entirely eliminating, qualityrelated issues in the market.

Venter noted that confidence in plastic pipes (and in SAPPMA itself) is being tested by ongoing concerns in the marketplace. He called on all members to unite in the fight against inferior products, stating that winning this battle requires the full and active support of every stakeholder.

“Cutting corners creates uncertainty and damage to both reputation and trust. We must protect the industry and reassure the market of the reliability and safety of plastic piping systems,” says Venter.

Members are encouraged to repor t any suspected quality infringements to SAPPMA, particularly if backed by evidence such as samples or test results. Repor ts may be submitted anonymously, allowing whistleblowers to raise red flags without fear of reprisal.

Mixing of polymers One particular area of concern highlighted during the members meeting is the mixing of polymers, especially in HDPE materials, which can severely compromise the longterm performance of pipe products. SAPPMA approached the European Plastic Pipes and Fittings Association (TEPPFA) for input on the issue, and also hosted a webinar with expert Peter Serjensen, who confirmed the negative impact of such practices.

In response to these growing concerns, SAPPMA issued a media release earlier this year, warning consumers and stakeholders about quality risks. The Association has also updated its Guidelines and Notes to Purchasers and Users of Plastic Pipes to help buyers make informed decisions and avoid substandard products. This resource is now available on the SAPPMA website and will be circulated to members. All members are encouraged to share the guideline with their customers as part of their commitment to raising awareness and promoting quality in the industry.

As the industry stands at a critical juncture, SAPPMA remains resolute in its mission to uphold high standards, protect the reputation of plastic piping, and ensure the delivery of safe, reliable infrastructure solutions across Southern Africa.

For more information, visit www.sappma.co.za

JACQUES VAN ECK APPOINTED AS SAPPMA QUALITY MANAGER

Jacques van Eck, Quality Manager at SAPPMA

S

APPMA is pleased to announce the appointment of Jacques van Eck as Quality Manager, effective 1 July 2025.

Jacques is no stranger to the plastic pipe industry or the SAPPMA community, having had a long-standing and valued relationship with the organisation. Well-known and respected within the industry, Jacques brings with him a wealth of experience, in-depth technical knowledge, and a strong commitment to upholding quality standards.

In his new role, Jacques will be responsible for ensuring that all products manufactured by SAPPMA member companies fully conform to the relevant National Standards (SANS) and ISO specifications, as well as the internal requirements set out by SAPPMA. He will report directly to Jan Venter, CEO of SAPPMA. Jacques' core responsibilities include monitoring the quality assurance policies and procedures of member companies, overseeing compliance with the SAPPMA Code of Conduct, conducting regular audits, inspections, sampling, and laboratory testing, and resolving any quality-related issues by implementing corrective actions. He will also collaborate with Certification Authorities and accredited Test Laboratories, represent SAPPMA at SABS Technical Committee meetings, and drive continuous improvement across the sector.

In addition to his primar y responsibilities, Jacques will provide suppor t to SAPPMA’s consulting projects, such as welding procedure qualifications, inspections of welding machines, and on-site evaluations – although these will remain secondary to his main quality assurance function. He will also actively participate in SAPPMA meetings, marketing activities, training modules, and webinars.

“Jacques’ appointment as Quality Manager is a major win for SAPPMA and our members,” says Venter. “His deep understanding of the technical requirements, combined with his passion for quality and integrity, will significantly strengthen our quality assurance function.”

Adds Jacques: “I’m honoured to take up the position of Quality Manager at SAPPMA. Quality and compliance are non-negotiable in our industr y, and I am looking for ward to working closely with members to uphold the high standards that SAPPMA is known for.

I’m excited to contribute to the industry in this new capacity and to be part of a dynamic team that prioritises excellence.”

Exhibitions & Networking Opportunities

Jacques van Eck SAPPMA Ensuring Quality HDPE Piping Systems

Kirtida Bhana Plastics SA Infrastructure Needs People: Why Training is the First Pipe Laid

Mike Smart Genesis Labour The PVC Pipe to Trump Traditional PVC-U and PVC-M

Renier Snyman Sun Ace SA The significance of Dichloromethane testing on PVC pipe performance OUR MAIN SERVICES:

SAPPMA members: R2500 + VAT RAIL FREIGHT Non-members: R3500 + VAT

Justin Marsberg CEISLAB The AENOR scheme for Plastic Piping System Certification Our Commitment with SA Market

Mike Schutte HDPE Solutions: Why polyethylene?

www.sappma.co.za

Plus access to international keynote speakers at the Southern African Vinyls Association’s conference,

www.reallygreatsite.com Anywhere St., Any City “The+123-456-7890 PVC Transformation: Driving Progress in a123 Changing World”

Register online: www.savinyls.co.za/events

PIPELINES – BULK & RETICULATION

ENGINEERING STANDARDS IN WATER INFRASTRUCTURE: A CALL FOR EVIDENCE-BASED DESIGN PRACTICES South Africa’s water infrastructure faces unprecedented challenges. According to the South African Institution of Civil Engineering’s latest Infrastructure Report Card, the country requires substantial investment in water infrastructure to meet current and future demands. With municipal budgets under constant pressure and the consequences of infrastructure failure potentially severe, every engineering decision must be based on sound technical principles and rigorous analysis. By Ian Venter

A

s technology and industr y partners, we have observed varying approaches to presenting technical information about plastic pipe systems to the market, but the ultimate responsibility in terms of specification rests with the engineering profession. While innovation in materials and design methods should be welcomed, the engineering profession has a fundamental obligation to ensure that all technical claims are supported by comprehensive analysis and verifiable performance data.

This article establishes a framework for evaluating technical claims and emphasises the critical importance of evidence-based engineering practice in infrastructure development. When resources are limited and public safety is paramount, the professional community must maintain the highest standards of technical integrity.

Beyond simplified comparisons While parameters such as ring stiffness provide helpful information, they represent only one aspect of structural performance.

Ring stiffness, calculated using the formula RS = E × I / D³ × (1 + μ) – where E is elastic modulus, I is moment of inertia, D is diameter, and μ is Poisson’s ratio – provides information about a pipe’s resistance to external loading under idealised conditions. However, this

18 IMIESA July 2025

simplified approach cannot account for the complex interactions that occur in real-world installations.

A professional engineering analysis must also consider: • Soil structure interaction: Here, the behaviour of buried pipes is significantly influenced by soil properties, backfill quality, and installation methods, which cannot be fully captured in simplified calculations.

• Material behaviour over time: Many pipe materials exhibit time-dependent properties, including creep and stress relaxation, that affect long-term performance and must be analysed using appropriate models.

• Loading conditions: Infrastructure must withstand various loading scenarios, including static earth loads, traffic loading, and dynamic effects, which require comprehensive analysis methods.

Professional designers ensure thorough and reliable engineering by utilising trusted resources, including the Red Book for planning, SANS codes for technical specifications, and municipal guidelines for local compliance. They also follow SANS ISO 16422:2016, Pipes and joints made of oriented unplasticised poly(vinyl chloride) (PVC-O) for the conveyance of water under pressure specifications standards and apply comprehensive analysis techniques to reflect real-world conditions in water infrastructure projects.

PIPELINES – BULK & RETICULATION

ABOUT THE AUTHOR Ian Venter launched Polymers and Piping (fittings) Systems South Africa (PPfSSA) in June 2024. The company specialises in consulting on how manufacturers and end-users can consistently achieve high-quality thermoplastic products, and provides comprehensive solutions for piping systems. Ian holds a National Higher Diploma in Polymer Technology and has made significant contributions to advancing industry standards in his field.

For further information, phone +27 82 770 8244 or e-mail: IanVenter@PPfSSA.com.

South African design considerations South Africa presents specific challenges for buried infrastructure, including diverse geology with varying soil types, significant temperature variations across regions, varying levels of construction expertise, and limited municipal maintenance resources. These factors necessitate robust design approaches that consider real-world implementation constraints.

Safety factors are fundamental requirements established through decades of engineering experience and codified in international standards. ISO 16422-2:2024 specifies minimum safety factors for different loading conditions.

For pressure applications, these entail a 2.5 working pressure to failure pressure, a 3.0 service load to ultimate capacity, and a fatigue loading of 5.0, representing the service stress to fatigue limit in terms of fatigue loading.

Key differences in safety factors: Pressure vs non-pressure applications In pipe system design, safety factors differ between pressure and non-pressure applications. For pressure pipes, factors are higher: 2.5 for working pressure to failure, 3.0 for service load to ultimate, and 5.0 for fatigue loading, due to greater cyclic stresses.

Non-pressure pipes focus on resisting external loads, with lower service and fatigue safety factors (1.5–2.0), and emphasise deflection (factor of 4.0) and buckling (3.0–4.0).

Tailoring these factors ensures reliable, longterm performance under application-specific demands.

It must be noted that the Construction Regulations of 2014 (Government Notice R84) establish mandatory legal requirements for structural design, with Regulation 6(1)(a) specifically obligating designers to “ensure that the applicable safety standards incorporated into these Regulations under section 44 of the [Occupational Health and Safety] Act are complied with in the design.”

The Engineering Council of South Africa’s (ECSA’s) Code of Conduct creates legally binding professional obligations: registered persons are required to execute their work “with integrity and sincerity and following generally accepted engineering practice,” and to adhere to “accepted engineering practice, standards and applicable codes.”

This framework creates a two-tier system of legal compliance – direct adherence to incorporated standards (such as SANS 10085 for scaffolding) and the professional duty to follow relevant SANS codes that define accepted engineering practice, including SANS 10252 for building installations, SANS 1200 series for bulk infrastructure, and SANS 16422 for PVC-O pipe systems.

Non-compliance can result in criminal liability under the Occupational Health and Safety Act, professional disciplinary action by ECSA, civil liability for damages, and even project shutdowns by labour inspectors.

This integrated regulatory and professional approach ensures that water and sanitation infrastructure meet both statutor y safety requirements and the standards of sound engineering mandated under South African law. In this context, the Red Book, SANS codes, and municipal guidelines together form a legally binding framework for professional engineering practice in the country.

Design methodology comparison: the critical difference To illustrate why comprehensive analysis and appropriate safety factors are essential professional requirements, we present a comparative analysis of two contrasting design methodologies commonly encountered in current practice for the construction of municipal water mains.

In this example, the application involves a 300 mm (DN300) pipe diameter, an operating pressure of 10 bar (1.0 MPa), an installation depth of 1.5 m, medium-density sand as the soil condition, a design life requirement of 50 years, and the use of a PVC-O pipe system.

Methodology A: Simplified approach This methodology, unfor tunately, is still promoted in some technical literature and relies primarily on basic parameter comparisons: • Characteristics: This methodology uses simplified ring stiffness calculations as the primary design criterion, applies safety factors below international standards (1.5 for pressure, compared to the required 2.5), relies on nominal material properties without considering variations, ignores longterm material behaviour and degradation effects, and assumes ideal installation conditions.

• Analysis process: The basic pressure calculation uses nominal material strength, ring stiffness is compared against simplified criteria, wall thickness is selected from manufacturer tables, minimal consideration is given to soil conditions or loading scenarios, and no long-term performance analysis is conducted.

• Professional compliance issues: This methodology does not meet the ISO 164222:2024 minimum requirements, falls shor t of SANS standards for comprehensive

IMIESA July 2025

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PIPELINES – BULK & RETICULATION

analysis, may violate Construction Regulations 2014 requirements, and creates potential exposure to ECSA professional misconduct.

Methodology B: Professional standards approach This methodology follows established international standards and professional engineering requirements: • Characteristics: Comprehensive structural analysis encompasses soil structure interaction, the complete application of ISOspecified safety factors (2.5 for pressure and 3.0 for structural), consideration of material proper ty variations and uncer tainties, long-term per formance analysis that incorporates creep and degradation effects, and a realistic assessment of installation conditions and tolerances.

• Analysis process: The pressure design utilises minimum required strength

values with appropriate safety factors, complemented by comprehensive structural analysis that addresses all loading conditions, deflection limits, and soil interaction. It also includes long-term performance evaluations, time-dependent effects, fatigue analysis for cyclic loads, and considerations for installation tolerance and quality control.

• Professional compliance: This methodology meets ISO 16422-2:2024 requirements, complies with SANS standards for structural analysis, satisfies Construction Regulations 2014 obligations, and maintains ECSA professional conduct standards.

Critical differences and implications Potential risks of simplified approaches include inadequate pressure capacity under normal operating conditions, excessive deflection leading to joint failure and ser vice disruption, premature failure due to unaccounted long-term ef fects, and installation sensitivity, which creates quality control challenges.

Furthermore, simplified methodologies often ignore time-dependent effects such as creep, which can significantly reduce structural capacity over the design life. Professional analysis includes these effects to ensure adequate long-term performance.

Therefore, while simplified approaches may appear to offer initial cost savings, industry experience suggests that long-term economic impact typically favours robust professional design due to reduced failure probability and longer service life.

For a 100-year design life Joint design becomes the critical determinant of system longevity, requiring the prioritisation of integral socket joints with factory-moulded

20 IMIESA July 2025

EPDM seals, the implementation of enhanced safety factors beyond standard requirements, and stringent installation procedures, including conser vative angular deflection limits (≤1° vs. the standard 2° per joint) and precise dimensional control.

Success depends on factory quality control, including batch testing of seal compounds, cer tified installer requirements with independent joint inspections, the selection of high-per formance EPDM materials with proven long-term ageing resistance, and comprehensive documentation that includes seal material traceability and installation records. While PVC-O pipe material can easily exceed 100-year performance, the system’s actual ser vice life is determined by joint integrity, installation quality, and long-term maintenance of the sealing system, making joint design the primary focus for extended design life applications.

Downstream implications Engineers who use simplified methodologies face increased professional liability exposure due to non-compliance with established standards and potential consequences of failure.

Professional risks include possible ECSA disciplinary action for substandard design practice, exclusions in professional indemnity insurance coverage, personal liability exposure for failure consequences, and damage to reputation with potential career impact.

Material selection: A systematic approach In all respects, the selection of pipe materials for infrastructure requires systematic evaluation, starting with technical performance criteria. Structural adequacy under all design loading conditions, long-term durability under anticipated service conditions, resistance to relevant environmental factors, and compatibility with existing infrastructure systems are critical considerations in the selection process.

Additionally, initial capital costs – including materials and installation, as well as operation and maintenance costs over the design life, expected service life under local conditions, and end-of-life disposal considerations – are key economic factors.

Equally vital are the implementation considerations, including the required skills and technical capacity, as well as the availability of construction equipment and resources.

Additionally, quality control requirements and

PIPELINES – BULK & RETICULATION

procedures are essential implementation considerations.

Performance validation requirements Material selection decisions should be based on verified performance data rather than theoretical projections. The following are the key validation criteria to note: • Standards compliance: Verification that materials meet applicable South African National Standards (SANS) and relevant international standards such as ISO specifications.

• I ndependent testing: Per formance verification through independent testing laboratories using standardised test methods.

• Field performance data: Where available, actual per formance data from similar applications under comparable conditions should be referenced.

• Conservative analysis: When performance data is limited, conservative assumptions should be used to ensure adequate safety margins.

Overall, technical evaluation criteria must prioritise long-term value over initial cost, which is a core priority for project owners and municipalities in addressing and overcoming premature failures in pipeline performance.

Alongside engineering best practice, innovation in pipe technology and design methods should also be encouraged, but must still be supported by appropriate validation processes. New technologies must be validated through carefully monitored installations with comprehensive performance data collection over extended periods. Successful innovations should then be incorporated into appropriate, peer-reviewed technical standards through established development processes.

Conclusion: Excellence through professional discipline Our A and B methodology comparison demonstrates that professional engineering standards are practical requirements that determine infrastructure per formance, economic outcomes, and professional liability exposure.

Pressed Steel Sectional Water Tanks

Simplified design approaches that rely on basic parameter comparisons and inadequate safety factors create unacceptable risks, including potential premature failure, increased lifecycle costs, and professional liability exposure. These methodologies violate established professional standards and legal requirements.

In contrast, comprehensive professional design following ISO 16422-2:2024 and related standards delivers reliable long-term performance, optimised lifecycle economics, and full compliance with professional and legal obligations.

South Africa’s infrastructure challenges require the highest standards of professional engineering practice. The engineering community must commit to comprehensive analysis, incorporate appropriate safety factors, and adhere to evidence-based design practices. The tools, standards, and knowledge exist to deliver worldclass infrastructure. What is required is the professional discipline to apply them consistently.

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RESERVOIRS

Corestruc constructs solid foundations in the water infrastructure market Having already successfully delivered about 600 Mℓ of water storage capacity throughout the country over a very short period, Corestruc has not only grown a formidable presence in the water infrastructure market. The company has also brought the role that precast concrete technology can play in streamlining the delivery of quality water supply infrastructure to the fore.

F

or many municipalities, water service authorities and water intensive industries, including mines, constructing entire reservoirs and water towers with high quality prefabricated concrete elements is a given. This is considering the technology’s proven track record in accelerating the construction of this complex infrastructure.

Using cast-in-place methods, there is very little scope for error. To achieve durable and liquid retaining structures, a suitable design must be well executed during construction and according to exacting specifications. It is also an extremely lengthy process.

Using Corestruc’s method, reservoirs, ranging in size from 200 Kℓ to 50 Mℓ, have been built in a fraction of the time. In turn, this has helped to fast-track access to an essential service and basic human right enshrined in the South African Constitution.

This while also providing municipalities with a more affordable reservoir construction solution. Significant cost savings are also achieved over the long lifecycle of these structures, which feature denser, stronger and more resistant concrete elements.

This is the outcome of high standards of quality control in the world class factories where they are manufactured. For example, controlled curing processes ensure that concrete sets under the ideal conditions to maximise the strength of the elements. They are also stress-tested before they are dispatched to site and inspected again before they are integrated.

This process also eliminates unknowns that influence the quality of cast-in-place concrete such as temperature, humidity and inaccurate Corestruc has designed and built Africa’s first precast concrete water tower

Corestruc’s reservoirs have won many industry awards for concrete design and application excellence

22 IMIESA July 2025

RESERVOIRS

tools. It is a fact that many reinforced concrete structures are requiring major repairs very early on in their useable lives. In many instances, this can be attributed to shoddy workmanship. This increases total cost of ownership and places an additional financial burden on stretched municipalities, which are already struggling to keep pace with maintenance requirements.

District municipalities take the lead The potential role that precast concrete could play in streamlining water storage capacity was first identified by Thembisile Hani Local Municipality (THLM) and its professional teams.

Working alongside Corestruc, it helped to refine and set the standard in precast concrete reservoir design and construction. This paved the way forward for more district municipalities to innovate in the field.

THLM accelerated the construction of two 10 Mℓ reservoirs in its jurisdiction. One of these was part of the Bundu Water Augmentation Scheme, the largest infrastructure project to be undertaken by the municipality to date. It is therefore regarded as a flagship structure by the municipality. This is especially considering that it received a 100% score in the Department of Water and Sanitation’s 2023 Blue Drop report. Following almost five years of operation at the time, the report noted that the reservoir was leak-free and in a very good condition.

Partnering with Corestruc, Vhembe District Municipality (VDM) also built two 10 Mℓ precast concrete reservoirs to help alleviate severe water shortages in its jurisdiction.

Again, significant construction time and cost savings were achieved. Each reservoir was

Corestruc’s precast concrete reservoirs are constructed quickly and cost-effectively

completed in only four months. It would have taken about nine months to build a similar sized water retaining structure with in-situ construction methods. This impressive feat earned the project a prestigious Concrete Society of Southern Africa 2025 Fulton Award in the “Innovation and Invention” category.

By facilitating faster and more cost-effective reser voir construction, precast concrete addresses two of the biggest hurdles that stifle construction of critical service delivery infrastructure in smaller outlying municipal jurisdictions. As a result, many communities have had to contend with erratic water supply for extended periods.

However, VDM and THLM are not the only municipalities that view this as an opportunity to find innovative solutions to unique challenges.

Capricorn District Municipality, Steve Tshwete Local Municipality, Dr JS Moroka District Municipality, Nala Local Municipality, Setsoto Local Municipality, Polokwane Local Municipality and Thulamela Local Municipality have also engaged Corestruc to help accelerate reservoir construction.

Hybrid approaches In some instances, precast concrete technologies have been deployed together with in-situ concrete methods to fast-track the construction of these structures. For example, Corestruc has built many reservoir roof structures, which are the most complex

and time-consuming components of a conventional water retaining structure construction project.

The large roof structure of the 50 Mℓ Krugersburg reser voir in Polokwane is a stellar example of hybrid concrete construction excellence. By incorporating a precast concrete roof into the design, the build was fast-tracked to supply an influx of tourists to Polokwane during the FIFA 2010 Soccer World Cup. Corestruc has also provided such solutions to Magalies Water, including for the 50 Mℓ Mafenya reservoir, which was highly commended by judges in the 2017 edition of the Fulton Awards.

The need for municipalities, especially those that face deep-rooted development obstacles, to challenge the norm was recently reiterated by Dr Nomalungelo Gina, Science, Technology and Innovation Deputy Minister.

“Innovation allows us to ‘leapfrog’ to better outcomes. New technologies disrupt the status quo, reduce costs and streamline processes, ultimately empowering citizens and restoring trust in local government,” she elaborated.

Metropolitan municipalities break boundaries However, it is the metropolitan municipalities that are driving Corestruc to test perceived limitations of precast concrete so that they

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RESERVOIRS

Winterveld project

The precise manufacture of precast concrete elements facilitates quick integration on site

can ensure water security in their jurisdictions.

Rapid urbanisation is placing significant strain on their existing supply capacity.

With the help of Corestruc, the City of Ekurhuleni Metropolitan Municipality (City of Ekurhuleni), for example, has constructed Africa’s first prefabricated concrete water tower. This project also deservedly won a 2025 Fulton Award in the “Infrastructure of up to R100-million category”. The panel of judges was impressed by the “exceptional quality of the

The precast concrete elements are inspected again before integration as part of quality control

24 IMIESA July 2025

precast concrete, as well as the speed at which this type of infrastructure can be provided with the associated cost savings.”

Working alongside Corestruc, the city’s Water and Sanitation Department has also built seven high quality precast concrete reservoirs ranging from 25 Mℓ to 30 Mℓ in size. These projects have also helped to meet City of Ekurhuleni’s strategic socio-economic objectives.

Opportunities for contractors Working alongside Corestruc as the main contractors, black-owned mid-tier construction companies have accumulated a wealth of knowledge and experience in large reservoir construction projects. Equipped with an intricate understanding of the system and Corestruc’s processes, they have a strategic competitive edge when tendering for more of these projects.

Their value proposition is the ability to construct them faster and more cost-effectively.

RSMM Construction, Anita Building Construction, Mbako Projects and Trading, and Morawa Building & Civils have all made a name for themselves in the water retaining structures market. This is at a time when municipalities are mustering available resources to address a growing backlog in water and sanitation infrastructure. An investment of around R70,4 billion a year is required to address water scarcity, alone.

Johannesburg Water, for example, is investing heavily in upgrading water infrastructure.

Corestruc has also participated in these projects.

Meanwhile, the City of Tshwane Metropolitan Municipality is the latest large municipality to start building a precast concrete reservoir.

By fast-tracking the construction of 25 Mℓ of additional water storage capacity, the municipality will bring urgent relief to Winterveld. This rapidly expanding informal urban settlement has been grappling with severe water shortages.

Similar to Corestruc’s other reservoirs, it consists of a precast concrete roof and prefabricated “slide-and-pinned” wall system.

Post-tensioning is undertaken when the wall is not yet fixed to the ring footing and it is, therefore, allowed to slide on a steel bearing or locating plates. The coated post-tensioned cables are not bonded to the grout, with the reservoir designed to maintain a residual compression of a minimum of 1 MPa in all directions.

Horizontal reactions to the wall base are transferred to the ring foundation through the second phase cast in-situ kicker. This is where the ring tension in the base is also activated to resist the reaction. Additional post-tensioning of the lower part of the wall reduces the amount of reinforcing bar required in the cast-in-situ ring footing.

As part of the final aspects of the build, the concrete floor slab is completed and the hollow core slabs that make up the outer portion of the roof structure are connected to the precast concrete beams. A grout topping is then placed over the hollow core slabs to form a single monolithic structure and a precast concrete coping installed around the perimeter of the roof as an aesthetic finish.

Second water tower for Ekurhuleni Meanwhile, Corestruc is also finalising the construction of the second precast concrete water tower for the City of Ekurhuleni Metropolitan Municipality. Located 34 m above ground level and with a diameter of 18 m, the tank has a capacity to store 3,5 Mℓ of water. It comprises precast concrete wall panels and a prefabricated concrete roof structure, consisting of 150 mm thick hollow core slabs supported by four internal precast concrete columns and beams.

The structure’s columns were cast to individual lengths to fit between the spiral beam levels. In turn, the spiral beams were cast in segments to complete a 30° rotation for each

RESERVOIRS

beam. Besides the aesthetic value of the spiral beam, it provides critical lateral support to the columns.

Cast in a “U” shape, these precast concrete elements were made continuous by installing site placed rebar and filling them to the brim with cast-in-place concrete. The structure’s columns were made continuous via cast-in threaded sockets and installing dowels into the receiving sleeves that were filled with non-shrink grout.

Each node point was designed to withstand the prescribed lateral notional loads, as well as possible seismic action in combination with axial loads.

Continuity of the composite spiral beam was achieved by introducing cast-in female sockets to the bottom of each column below the castin-place concrete level. These sockets then received threaded dowels that spliced into the main rebar, which was placed into the U-shape precast segment while still on ground level.

Supporting the centre of the tank and housing the stairs and pipes, the central shaft consists of individual precast concrete rings, each about

Robust and Reliable

Water Storage

1,6 m in height. These rings are connected to each other via bespoke cast-in mechanical connectors, which also doubled as a line-up and levelling mechanism. The recess pockets for the components were closed with grout on site to protect against corrosion.

Allowable maximum transpor t width determined the diameter of the central shaft.

It was extremely challenging to fit the 600 mm diameter and 500 mm diameter inlet and outlet pipes, in addition to the access stairs inside.

On top of the columns, tapered precast concrete beams connect the columns to the shaft at tank floor level, where hollow core slabs were used as a permanent shutter to cast a 350 mm thick in-situ floor.

The tank floor beams were designed to support the weight of the precast slabs with the weight of the wet concrete while still in the virgin precast state. It was designed as a composite with the cast-in-place floor to withstand service loads. The cantilever along the perimeter caused an enormous negative moment over the column positions. This was countered with sufficient top

steel in the cast-in-place floor that formed the composite top flange of the beam.

High levels of accuracy were maintained in setting out the prefabricated concrete elements via co-ordinates. They were manufactured to exacting standards in Polokwane and transported to site where they were placed with a 150 t hydraulic crawler crane.

In addition to these projects, Corestruc is currently constructing a 3 Mℓ reservoir in Vondo and Vryburg, a 10 Mℓ reservoir in Paulpietersburg and a 25 Mℓ reservoir in Klipvoor village.

“Across the country, reliable water access is just 64%. Therefore, water provision cannot be taken for granted, requiring continuous investments in infrastructure. At the same time, considering the extent of the challenge with which we grapple as a countr y, we need to ‘box smart’. This is by continuously finding ways to deliver higher quality services infrastructure in a more practical and costeffective manner,” concludes Willie de Jager, Managing Director of Corestruc.

ADVANTAGES • Highly economical cost to volume ratio • Easily transportable, especially for multiple tanks • Easy assembly, even at elevated heights • NO CRANES REQUIRED • Robust steel tank with high life expectancy • Replaceable liner allows for extended life

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MEYERTON | Tel: 016 362 9100 Sales & Marketing: Godfrey Mpotu, contracts@structatech.co.za | 079 035 6997 Estimator: Judy van der Walt, watertanks1@structatech.co.za Director: Rodney Cory, rodney@structatech.co.za | 082 575 2275

www.structatech.co.za | www.circotank.co.za

INFORMATION & COMMUNICATIONS TECHNOLOGY

ELEVATING THE BUILT ENVIRONMENT AI-powered generative design allows for the rapid generation of hundreds of design iterations – potentially 500 in the time it once took to create five – by leveraging computational methods, such as genetic algorithms or machine learning models

The transformative nexus of AI, BIM, and digital twinning Ar tificial intelligence (AI), Building Information Modelling (BIM), and digital twinning have swiftly moved from decades of theoretical debate to real-world applied methodologies. Across the world and in South Africa, these technologies are now rapidly reshaping the contemporar y engineering landscape, and the benefits are profound. By Devesh Mothilall

A

s the global construction market navigates a valuation of US$1.4 trillion, these technologies are not merely trends but fundamental shifts in project deliver y. The central enquir y guiding this discussion is how these advancements are redefining what is possible within our industry, addressing critical questions such as how construction challenges might be predicted before they materialise.

However, despite its immense global footprint, the construction industry has historically been one of the least digitised sectors. But that perceived resistance is changing fast. Simply put, traditional methodologies are increasingly unsustainable, given today's complex and resource-constrained environments, and early adopters were the first to recognise this.

26 IMIESA July 2025

Today we therefore stand at a pivotal juncture where digital technologies are poised to revolutionise how we design, construct, and manage our built environment, representing a fundamental shift in project delivery. And there’s no turning back.

The AI revolution: Enhancing design and prediction That’s because the integration of AI into engineering workflows has resulted in a profound paradigm shift. AI-powered generative design, for instance, allows for the rapid generation of hundreds of design iterations – potentially 500 in the time it

once took to create five – by leveraging computational methods, such as genetic algorithms or machine learning models.

These algorithms explore vast design spaces, optimising outcomes based on specified parameters, including structural integrity, material ef ficiency, and cost constraints. Specific software platforms like Autodesk Forma and Hypar, or custom scripts using Python libraries such as TensorFlow or PyTorch, exemplify these capabilities in civil engineering and architecture.

Beyond design, AI's predictive analytics capabilities empower proactive project risk management with an impressive 78% accuracy.

This is achieved by analysing historical project data – such as past schedules, budgets, change orders, weather patterns, material delivery times, and resource allocation – alongside realtime inputs.

Real-time data can include sensor readings from existing infrastructure (e.g., strain gauges on bridges, flow meters in pipelines,

Devesh Mothilall, Head of Digitalisation: Smart City Office, and Head of Knowledge Hub: ECOE at the City of Johannesburg

INFORMATION & COMMUNICATIONS TECHNOLOGY

traffic sensors, etc.), geospatial information, drone imagery, weather forecasts, and real-time site progress updates from BIM models. Within this context, AI algorithms, including regression analysis, classification models, and neural networks, learn patterns from this aggregated data to identify correlations and predict future outcomes or potential failures.

Energy management and sustainability through AI In an era where sustainability is paramount, AI-driven systems also provide granular insights into energy consumption patterns – our most vital socioeconomic resource after water. Here AI facilitates the identification of inefficiencies and the implementation of targeted waste minimisation strategies. Optimising heating and cooling systems, for example, can lead to substantial reductions in energy use.

Furthermore, AI actively enables the integration of renewable energy sources, significantly contributing to greener construction practices and a lower carbon footprint.

For infrastructure in a South African context, AI offers actionable solutions for energy management and sustainability that, when implemented effectively, have major benefits.

This includes: • Traffic management: Here AI optimised traffic light sequencing based on real-time traffic flow helps to reduce idling times, fuel consumption, and emissions in urban areas.

• S mar t grids: AI in municipal energy management, predicting demand, integrating intermittent renewable sources (such as solar and wind) and optimising energy distribution within local grids to minimise waste and blackouts.

• Water management: AI optimising pump schedules in municipal water networks to reduce energy consumption while maintaining pressure and supply. Imagine, for instance, a hypothetical South African scenario where AI could be applied to an entire municipal water network, learning peak demand cycles and adjusting pump operations to significantly reduce electricity consumption during offpeak hours, thereby leading to substantial municipal energy savings.

In this respect, object-based modelling can reduce spatial coordination errors by up to 40%. This is primarily due to clash detection tools (e.g., Navisworks, Solibri, etc.) that automatically identify interferences between different building systems – architectural, structural, mechanical, electrical, and plumbing – before any physical construction begins, preventing costly rework.

Central to BIM collaboration is the Common Data Environment (CDE), which ensures all project stakeholders work from the latest, synchronised information, significantly reducing miscommunication and rework.

BIM's object-based nature also allows for precise quantity take-offs, automated cost estimations, and integrated scheduling, all contributing to enhanced efficiency and reduced material waste, while enabling calculations of precise carbon footprints and simulations of aspects like energy performance even before breaking ground.

Digital twins: The future of asset management Because digital twins are virtual replicas of physical assets, they offer unprecedented opportunities for real-time monitoring and management. By integrating data from sensors and Internet of Things (IoT) devices, digital twins continuously track project performance, essential for detecting deviations and forecasting potential challenges. Here, the Virtual Singapore project serves as a global benchmark for urban planning, allowing city planners to test scenarios and predict outcomes in real-time.

However, while the benefits are clear, the adoption of digital twins remains nascent in the industr y. This is largely due to technological complexities and the need for standardised data formats. Key challenges include: • Data integration: The difficulty in bringing together data from disparate sources like BIM models, IoT sensors, Geographical Information Systems (GIS), and enterprise systems (e.g., ERP/CMMS), which often use different formats and protocols.

• Interoperability: The lack of seamless communication between various software platforms and hardware devices.

• Data volume and processing: The sheer volume of real-time data generated by IoT devices necessitates robust data storage and processing capabilities, often requiring edge computing or cloud platforms.

• S tandardisation: The critical need for industry-wide protocols (e.g., IFC for BIM, ISO standards for IoT data) to ensure consistent data exchange and semantic interoperability.

Application scenarios In South Africa, while direct widespread examples are still emerging, the application of digital twins in municipal infrastructure presents significant opportunities. This could include a pilot project for a municipal water treatment plant or a key piece of transport infrastructure being digitally twinned for per formance monitoring and predictive maintenance. Hypothetically, a digital twin of a municipal road network could enable real-time

The role of BIM: A collaborative revolution Let’s now talk about BIM in the mix. Firstly, it’s important to emphasise that BIM extends far beyond mere 3D modelling, with its digital twinning advantages; it represents a collaborative revolution that is data driven.

AI integration with SCADA systems is taking intelligent process control to unprecedented levels

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INFORMATION & COMMUNICATIONS TECHNOLOGY

AI actively enables the integration of renewable energy sources, significantly contributing to greener construction practices and a lower carbon footprint

traffic analysis and optimised maintenance scheduling, addressing local infrastructure challenges.

Then there are the oppor tunities for predictive maintenance frameworks, powered by machine learning algorithms within digital twinning environments. This would serve to predict component failure probabilities, optimal maintenance windows, and resource allocation strategies – all per fected via machine learning (ML).

The advantages of ML are wide-ranging and include: • Anomaly detection: Identifying deviations from normal operational parameters (e.g., unusual vibrations, temperature spikes, pressure drops, etc.).

• Pattern recognition: Learning patterns that precede failures from historical data.

• ML models: Utilising types like support vector machines (SVMs), random forests, or neural networks, which are trained on sensor data to predict the remaining useful life (RUL) or likelihood of failure.

Challenges and mitigation strategies Despite the clear benefits, however, the widespread adoption of these technologies still faces significant challenges.

28 IMIESA July 2025

Cost remains a primary barrier, cited by 23% of construction professionals globally.

Within the South African context, this challenge is often compounded by fragmented legacy systems in municipalities and varying BIM maturity levels across local design firms, exacerbating interoperability issues and data standardisation complexities.

Other key challenges include: • Data security and ownership: Cybersecurity threats pose significant risks to sensitive project information.

• Cultural resistance: A prevailing reluctance within the industry to change established practices.

• Workforce upskilling: An urgent need for continuous learning among professionals to integrate advanced technologies.

These challenges, however, should be viewed as oppor tunities for strategic development. Mitigation strategies include phased technology adoption; strategic skills development and continuous learning programmes; cross-industr y knowledge transfer and the creation of cross-functional innovation teams; and the development of internal digital transformation roadmaps.

Future trends and economic implications Looking ahead, the integration of AI with digital twins promises enhanced predictive capabilities that can revolutionise project management. Anticipated benefits include potential efficiency gains of 4060%, cost reductions of

20-35%, and the ability to mitigate carbon emissions by up to 25% through smar t digital technologies. The convergence of technologies such as edge computing in construction, advanced ML models, and blockchain for secure data management will further drive this transformation.

Either way, the economic landscape is undergoing a seismic shift, accelerated by the COVID-19 pandemic. Within this context, the International Monetary Fund estimates that AI will impact nearly 40% of all jobs, signifying a complete reimagining of work, productivity, and economic potential.

Within South Africa, the “digital metamorphosis” aligns with national and provincial strategies for smart cities and digital infrastructure. Local government initiatives promoting digital transformation in infrastructure, and increasing adoption rates of BIM, AI, or digital twins by South African engineering firms, underscore this trajectory.

Ethical considerations When applied proactively, generative AI has already demonstrated the ability to match or surpass human performance in complex tasks across various sectors, including energy, healthcare, aerospace, supply chain, and construction – pillars of the global economy.

But the primary intention is that it’s an advanced human-managed tool. This means that when we embrace AI, a commitment to ethical principles is paramount. Prioritising transparency, fairness, accountability, and privacy protection is crucial. In this regard, frameworks such as the White House's blueprint for an AI Bill of Rights guide this responsibility, underscoring that innovators are also ethical guardians of this transformative technology.

Conclusion Ultimately, the industry requires not merely digital transformation, but a digital revolution.

This presents an unparalleled opportunity to augment existing professional skills with advanced technologies, empowering engineers to build better, innovate more effectively, and solve complex problems.

Embracing these innovations as catalysts for change will redefine the industr y's future, unlocking new potentials that benefit both projects and the communities served. The journey ahead – navigating this exciting evolution – promises significant advancements for the built environment. It’s time to get on board.

LEGAL

CONSTRUCTION AND INFRASTRUCTURE DISPUTES

FORENSIC EXPERTISE STRENGTHENS LEGAL OUTCOMES Robert Palmer, Head of Afroteq Professional Services

As construction and infrastructure projects across Africa grow ever more complex, so too do the disputes that sometimes arise when timelines slip, costs escalate, or contractual obligations come under scrutiny.

R

esolving these disputes objectively and ef ficiently requires more than just legal argument. It demands clear, credible technical evidence and quantum calculations that can withstand the rigours of litigation and arbitration.

This is where forensic consulting services such as expert witness testimony, quantum calculations and delay analysis play a vital role.

By bridging the gap between technical complexity and legal process, these disciplines help courts and tribunals understand the facts, assign responsibility and determine fair outcomes.

Robert Palmer, Head of Afroteq Professional Ser vices, explains: “In construction and infrastructure disputes, the truth is often buried in thousands of pages of data, drawings, schedules and invoices. Our job is to extract that truth, explain it in clear, objective terms, and support the legal team with evidence that is both technically robust and legally admissible.”

In the field of exper t witness ser vices, independent specialists are called upon to provide impartial, fact-based testimony in legal proceedings. Across numerous highstakes cases, experts have helped arbitrators and judges navigate the intricate details of engineering failures, contractual breaches and project delays.

“Credible exper ts are valued not only for their deep technical, programme and financial knowledge, but also for their ability to communicate complex findings clearly and remain composed under cross-examination,” says Palmer.

Quantifying damages, costs and contractual entitlements Another cornerstone of dispute resolution is quantum calculation, which involves quantifying damages, costs and contractual entitlements.

For example, skilled forensic analysts can assess the financial impact of underpaid variations or disruption claims and provide valuations that stand up to scrutiny. In many cases, these analyses facilitate settlements before disputes escalate to formal hearings, thereby saving all parties time, money and uncertainty.

Equally critical is delay analysis, which examines construction schedules to determine why and how projects deviated from plan. Retrospective and prospective methodologies can uncover whether delays were due to contractor inefficiencies, unforeseeable external events, or clientdriven changes.

“These analyses don’t just help decide who is at fault. They also help legal teams tell a coherent, evidence-based story. That narrative is crucial for persuading a tribunal or judge. For example, we recently assisted in a case involving a collapsed and rebuilt ship loader. Delay analysis demonstrated that external factors beyond the contractor’s control caused the delays, leading to the dismissal of liquidated damages claims,” he explains.

As disputes become more complex, the value of disciplined, objective technical analysis is indisputable. For legal professionals navigating contentious construction and infrastructure matters, forensic experts offer more than just calculations and reports. They provide clarity, credibility and a more persuasive case.

Concludes Palmer: “Attorneys benefit most when they engage forensic experts early.

Beyond technical expertise, we understand the procedural and evidentiary demands of litigation and help legal teams avoid common pitfalls in document preparation, evidence presentation and risk assessment.

“Our expertise lies in shedding light on the technical issues and giving decision-makers the confidence to resolve disputes equitably.

Partnering with the right forensic experts can make all the difference in achieving a successful outcome.”

For more information visit www.afroteq.co.za or contact Afroteq Advisory Services on 086 002 2175

IMIESA July 2025

29

GEOTECHNICAL & ENVIRONMENTAL ENGINEERING

Resin injection counters stormwater induced subsidence When stormwater systems don’t function optimally, one of the most obvious signs is flooding. However, there’s another factor to consider, namely the undermining of structures due to stormwater pipeline joint leakages. IMIESA speaks to Tony Pappalardo, managing director at Uretek Geo Systems, about two case studies where their employment of Uretek’s proprietary geopolymer resin technologies have provided a sustainable remediation solution.

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ounded in Finland in 1977, Uretek’s invention of the slab lifting method set a new benchmark for ground improvement solutions. This was subsequently followed by the patented Uretek Deep Injection ® (UDI) process developed by Uretek in Italy. Today, these technologies are being implemented globally by Uretek’s licenced contractors on ground engineering reinstatement projects, with Uretek Geo Systems responsible for the Southern African market.

“The key advantage of Uretek’s geopolymer injection process is that it’s non-disruptive, as well as being a fast and efficient way to improve the loading conditions on sub-standard soils that have been directly affected by subsidence issues,” Pappalardo explains.

This proved to be the case for the reinstatement of an approximately 50 m long leaking stormwater pipeline in the Greenstone Hill area, bordering the Stoneridge Shopping Centre on Johannesburg’s East Rand, which had led to road settlement. A similar issue contributed to the destabilisation of concrete hardstand sections at a major distribution warehouse operation bordering OR Tambo International Airpor t. In both cases, Uretek Geo Systems was appointed by consulting engineers, United Asset Management, to effect the repair.

Remediation at Greenstone Hill Ser ving as an essential link to the Stoneridge Shopping Centre, the affected

30 IMIESA July 2025

CASE STUDY: GREENSTONE HILL – STORMWATER SEALING AND ROAD STABILISATION

Uretek Geo Systems’ team on site alongside the Stoneridge Shopping Centre. The scope of works required the non-intrusive repair of a leaking stormwater pipe using the Uretek Deep Injection® process to seal failed joints. This objective served two purposes, namely to retore pipeline integrity, and improve ground bearing conditions to counter road subsidence An injection tube being inserted into a drilled hole

Once each affected joint had been identified via camera inspection, small diameter holes were drilled from surface in preparation for the insertion of the injection tubes

GEOTECHNICAL & ENVIRONMENTAL ENGINEERING

Geopolymer injection is a nondisruptive, efficient alternative to conventional underpinning and piling which Uretek has advanced following over 30 years of research, development, testing and installation. The implementation of the Uretek geopolymer injection system can be categorised as proactive (improving the strength of soils to facilitate an increase in loading or combatting longterm settlement) or reactive (remediation of subsidence).

seal. In addition, the soils surrounding the pipeline were effectively consolidated and achieved correct realignment of the road sur face.

“As is routine on these projects, some of the geopolymer escapes into the interior of the pipe, which is then removed by a member of the technical team, ensuring that the remediated pipe remains clear for its intended function,” says Pappalardo.

“Ultimately, the repaired sections of the road – which were subsequently resur faced – showed significant improvement in stability, with no fur ther signs of water-induced deterioration during the next rainy season.”

Hardstand stabilisation access road required immediate attention due to safety and structural concerns. The stormwater pipe, situated approximately 1,5 m below the asphalt sur face, had several misaligned joints, leading to water outflows and the weakening of the surrounding load bearing soils.

During the rainy season, water percolated through these joints, travelling diagonally down the slope of the road. This resulted in the deterioration and breaking up of the asphalt sur face due to subsidence on the opposing two lanes of the double carriageway bordering Stoneridge.

“Remediation using excavation techniques would have been costly and time consuming, with an impact on downstream heavy traffic flows, as well as potentially reducing the number of visitors to the shopping centre.

This is where our UDI approach added major value, keeping road closures to a minimum during the remediation phase,” says Pappalardo, adding that the project was completed over two days in November 2023.

The star ting point was a push through camera inspection of the stormwater pipe to identify the leaking joints. The location of these joints was carefully mapped and transposed onto the road sur face above.

Uretek Geo Systems’ technicians then drilled small holes (14 mm diameter) through the road to reach and par tially penetrate the joints in preparation for the inser tion of the steel tubes required for resin injection.

Delivered via a mobile truck unit, as the pumped resin began to permeate through the joints, the injection process was paused to allow the material to expand and seal the leaks effectively. This step was repeated multiple times around the top and sides of the joints, ensuring a comprehensive

For the distribution warehouse project, a more intensive approach was required to address significant subsidence affecting sections of the approximately 20 000 m2 of

cast in-situ concrete driveway slabs within the facility’s southern zone. Operating 24/7, this centre caters for the constant movement of heavy-duty freight trucks. For this reason, a non-disruptive solution was again an overriding priority.

Remediation works were restricted to offpeak hours between 09h30 and 15h30, with additional work scheduled over weekends when traffic volumes were lower.

Due to the project’s large scope and budget constraints, work was executed in three phases over two years (2022/2023), with each phase completed ahead of schedule.

Factors for failure The settlement of the slabs was caused by two key factors working together, namely: • Deterioration of the original joint sealant between slabs, which allowed for water infiltration. This weakened the subsoil

CASE STUDY: STABILISING HARDSTANDS AT A MAJOR DISTRIBUTION WAREHOUSE

BEFORE

The combination of Uretek Slab Lifting and Deep Injection methods provided a longterm, cost-effective stabilisation solution for this hardstand area. Leaks through the slab joints, as well leakages caused by a misaligned underground stormwater pipe, destabilised concrete slab sections. In addition to slab lifting, some sections had cracked and needed replacement

AFTER

A fully restored driveway section

IMIESA July 2025

31

GEOTECHNICAL & ENVIRONMENTAL ENGINEERING

DISTRIBUTION WAREHOUSE STORMWATER REMEDIATION PHASE

Continuous monitoring via camera verifies the correct drill point breakthroughs on the pipe joints, as well as the resin injection pumping process

Polymerisation In terms of the process, the specified Uretek resin is injected at various points into the shallow area beneath each slab. Once injected, the resin expands horizontally and ver tically, following the path of least resistance, targeting areas with the greatest need for reinforcement. Thereafter, the resin expands ver tically, progressively transitioning from a liquid to a solid state via polymerisation. For subsidence remediation, this steady pressure on the underside of the affected slabs progressively lifts them back into their original position.

“Before drilling and injection, we cut the slab joints to separate individual slabs. This allowed for controlled, uniform lifting and realignment of each slab without unwanted stress transfer to adjacent slabs,” Pappalardo explains. The work zones were cordoned off in small sections, allowing for a systematic and controlled injection process.

“To verify the results, laser monitoring was used to track the lift and ensure precise levelling. Once all injection stages have been completed, the resin impregnated ground was virtually impermeable.”

Warehouse stormwater component Following the restoration of the slabs, the next phase has entailed the resealing of the main stormwater line. Work initially commenced on the first 70 m section in 2024. Uretek Geo Systems subsequently returned to site in June 2025 to complete the balance of the 600 m line, with works ongoing. Drilling depths range from 3 m down to 2 m.

A 3 m length drill rod employed on the distribution warehouse stormwater project

A sealed pipeline joint section following geopolymer resin injection. The pumped resin progressively transitions from a liquid to a solid state via polymerisation. Any excess resin escaping into the pipe interior is removed to ensure a smooth profile

and created voids beneath the slabs.

Over time, with constant heavy truck traffic, the slabs settled unevenly and became loose.

• A misalignment in the joints on the approximately 600 m long main stormwater line beneath the driveway.

This caused ensuing water flows to escape through sections with unsealed joints, exacerbating soil washout and fur ther destabilising the hardstands.

These two issues combined to create severe slab settlement and, in some cases, cracking. Some slabs had deteriorated beyond repair and needed full

32 IMIESA July 2025

replacement, requiring close coordination with a concrete contractor.

Uretek’s slab lifting and UDI technologies were selected as the optimal approach due to their ability to: - Recompact and stabilise the weakened subsoil by filling voids and restoring bearing capacity.

- Achieve 90% strength within 15 minutes, allowing for rapid reopening of work areas.

- Provide a non-intrusive solution, requiring only small diameter drill holes, and - Use of an eco-friendly, non-contaminating polymer that does not leach into the soil.

Conclusion The combination of Uretek Slab Lifting and UDI methods have provided a longterm, cost-effective stabilisation solution at the distribution warehouse, while UDI enabled a simple rehabilitation response at Greenstone Hill.

“These two case studies clearly demonstrate Uretek’s ability to deliver rapid, precise and environmentally friendly ground stabilisation solutions in a high traffic, time-sensitive environment, with minimal disruption,” adds Pappalardo.

“They also underscore the importance of ongoing monitoring of stormwater systems.

Early detection is the key to minimising downstream risks, but where infrastructure challenges do arise Uretek’s unique geopolymers ensure a complete restoration,” Pappalardo concludes.

88 IMESA TH

CONFERENCE

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IMESA ORGANISER

THE INSTITUTE OF MUNICIPAL ENGINEERING OF SOUTHERN AFRICA (IMESA)

RENEWABLE ENERGY & ELECTRIFICATION

Concor progresses on Karreebosch Wind Farm Concor has become an important construction partner in South Africa’s wind energy landscape and recently started work on the Cennergi Holdings and G7 Renewable Energies 140 MW Karreebosch Wind Farm.

Early project works undertaken by Concor include establishing access roads, site offices and an on-site batching plant, in preparation for the large volumes of concrete needed for the turbine foundations

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ocated between the towns of Matjiesfontein and Sutherland, Karreebosch Wind Farm is sited predominantly in the Northern Cape and will generate energy for a private off-taker.

At the heart of the project will be 25 turbines at a height of 100 m with blades over 84 m long.

Interestingly, the site of this project is adjacent to the Roggeveld Wind Farm which Concor completed about five years ago.

According to Stephan Venter, Contracts Director at Concor, the early work included establishing the necessary infrastructure on site, given the remote and rugged terrain. This will include access roads, site offices and a batching plant for the large volumes of concrete required for each turbine’s foundation.

Concor has begun constructing about 45 km of internal access roads, allowing the transportation of components and equipment to each turbine site. Roughly 200 000 m3 of blasting are likely to be required for the roads, foundations and other work. The G5 and G7 material for layer works will be produced on site, using jaw and cone crushers feeding a screen.

“The roads need to support the long heavy trucks used to transport turbine components,” says Venter. “For instance, the long turbine blades require the road design to provide sufficient turning radii as well as the right K-values to avoid trucks striking their undercarriage on uneven surfaces.”

Geotechnical groundwork In the early phases, Concor conducted detailed ground-line surveys and geotechnical investigations to understand the terrain. This helps in planning cut and fill operations, where material is removed from some areas and used to build up others – creating level roads that can support heavy loads.

Geotechnical work was critical to the integrity of the turbine foundations, and a specialised drilling company extracted 25 m cores at each turbine position. This established the founding conditions, allowing the foundation design to include the optimal bolt length for securing the turbine tower.

“The bolt length provides the key element around which we can finalise the design of the steel and concrete aspects of each foundation,” Venter explains. “This is vital preparation as the early stage designs can only rely on conventional geotechnical maps, which provide high level data rather than a detailed insight.”

He points out that the foundation design must also align with the loading documents that are specific to each turbine supplier. The planned

An aerial view captures on-site crushing in operation near one of the wind turbine base excavations

34 IMIESA July 2025

lifespan of these critical foundations tends to be longer than the 20 year off-take agreement, allowing for contract extensions that could see the turbines operating for up to 25 years.

The concrete foundations for each turbine measure over 20 m in diameter and are between 4 to 5 m deep, requiring about 600 m3 of concrete per foundation. The whole project will consume in the region of 25 000 m3 of concrete and 2 200 tonnes of reinforcing steel.

“We do our own concrete mix designs and will produce the readymix ourselves using aggregate from our Tweedside tillite quarr y 70 km from site,” Venter explains. “Material will be transported to our own batch plant on site, allowing us to cover most of the concrete value chain ourselves.”

The concrete turbine foundations will be poured continuously to ensure even curing, followed by thermal management to prevent cracking from temperature changes. Water for the batching plant will come from two carefully managed boreholes, which feed a 1,5 million litre water storage facility on site.

Among the environmental factors that the construction work will have to accommodate is the site’s proximity to the world famous astronomical observatory at Sutherland. This requires any night-time work to be conducted without creating light pollution that would affect visibility at the observatory.

“The concrete pouring cycle on each foundation lasts about 24 hours, which means that some tasks need to be done when it is dark,” adds Venter.

“We will take precautions by using special bulbs, for instance, and ensure that we only shine light downwards onto our work and not directly into the sky.”

CONSULTING ENGINEERS

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Royal HaskoningDHV South Africa becomes Atana

group of mostly South African engineering professionals who bought a controlling margin of the South African arm of Netherlands-based engineering consultancy Royal HaskoningDHV have rebranded it as Atana, effective from 1st July 2025.

The group – management and employees of the company – now owns 74% of what was Royal HaskoningDHV South Africa, with the Dutch business retaining 26% ownership. The South African operation of Haskoning became an independent company, owned by employees and local management, on 29th February 2024.

“Our rebrand as Atana highlights our strong focus on the pan-African market while building on 103 years of experience,” says Atana CEO, Anke Mastenbroek.

A B-BBEE Level 1 entity, Atana leverages cuttingedge technology, software and a multidisciplinary approach to address urgent challenges related to urbanisation, sustainable infrastructure and climate change.

Atana remains Haskoning’s (formerly Royal HaskoningDHV’s) strategic partner in Africa and

some of its practice areas will continue to deliver on global projects, specifically Atana’s data centre, light industry, climate resilience and aviation divisions.

Members of the Atana leadership team (from left): Pat van Wyk, Kevin Subramani, Kreanta Moodley, Sandhia Singh, Karen King, Abimbola Sole, Vidar Johannesen, Sumeshin Naidoo, Anke Mastenbroek and Andrew Mukanyima

A proud history Historically, the company that later became Royal HaskoningDHV South Africa was founded in Johannesburg in 1922 as Stewart Scott International. It gained significant international expertise when DHV Group acquired a majority shareholding in 2006.

In 2012, DHV and Royal Haskoning merged and became Royal HaskoningDHV South Africa. “Now, as Atana, we are enthusiastically returning to our African roots,” says Mastenbroek.

The name Atana is inspired by the Shona word zvakabatana, which means “closely connected”, and reflects a philosophy of integration, cohesion and success.

“Atana is filled with talented people committed to doing challenging work that makes a difference to South Africa, Africa and the globe. We want a world that is better, fairer and greener, so that everyone enjoys a more resilient society,” Mastenbroek concludes.

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WATER & WASTEWATER

Xylem Africa wins gold for safety at the RoSPA Awards 2024 Xylem Africa, the continent's leading vendor for pure water solutions and innovations, has been awarded the Gold Award for health and safety performance by the Royal Society for the Prevention of Accidents (RoSPA), the world's largest health and safety programme.

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or 2024, Xylem won a total of eighteen RoSPA Awards – fifteen Gold and three Silver – awarded to Xylem Water Solutions and Services (WSS).

Xylem Africa is proud to again be a part of the awards haul. Xylem's Cape Town site won its second consecutive Gold award, and Xylem's Kempton Park site in Johannesburg achieved its first Gold award.

The RoSPA Award recognises organisations that demonstrate an ongoing commitment to high safety standards. Earning so many awards is no small feat – a clear reflection of Xylem's vigilant and accountable safety culture, where care is front and centre.

“At Xylem, safety is the foundation of everything we do. Creating a safe environment is what allows us to deliver with excellence every day,” says Chetan Mistry, Xylem Africa's strategy and marketing manager.

“Safety is not a milestone – it’s a mindset.

By continuing to lead with safety, we build a stronger, more resilient WSS. Congratulations and thank you to every colleague who made this recognition possible."

(NEBOSH), the RoSPA Awards scheme is the longest running of its kind in the UK. It receives entries from organisations across the globe, making it one of the most sought-after achievement awards for the health and safety industry. Now in its 69th year, the awards receive almost 2 000 entries annually from over 50 countries – covering more than seven million employees.

Xylem Africa's engineering, workshop, and storage facilities once again demonstrated their safety standards and culture to the satisfaction of the RoSPA judges.

"NEBOSH is delighted to be the headline sponsor of the RoSPA Awards. Recognising excellence in health and safety is essential to ensure we celebrate achievement. But it is also about reinforcing a culture of care, accountability and continuous improvement,” says Dee Arp, NEBOSH Chief Quality Officer and the Head Judge of the RoSPA Awards.

“These awards serve as a powerful reminder that employee safety and wellbeing transcend borders, and looking after our people so they can go home safe, healthy, and happy every day also drives sustainable success and resilience.”

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36 IMIESA July 2025

Sensus, Godwin, and Lowara – and has a significant par tner network ser ving sectors from public utilities to commercial businesses and industry. Yet, it knows its people and their welfare are its greatest strength.

Safety training is about equipping employees with the skills and confidence to take action when it matters most. Xylem’s Health and Safety Framework is built on six pillars: • Leadership • Employee engagement • Communication • Risk management • Environment, Health, and Safety (EHS) systems, and • Data It has robust management systems, encompassing appropriate resources, effective structures, and strong governance, all establishing standards for monitoring health and safety performance. During 2024, Xylem employees completed 36 000 safety training hours in areas including compliance, safety leadership, and risk management.

Adds Julia Small, RoSPA’s Growth Director: “RoSPA regards Xylem as a strong example of the importance of making accident prevention central to any successful organisation, not just for the benefit of employees, customers and clients, but also society as a whole.”

WATER & WASTEWATER

Cape Flats water plant wins top architecture award The AWRP is a fundamental component of the Cape Flats Aquifer Management Scheme, which is expected to yield up to 54 million litres of water per day

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ompleted in December 2024, Cape Town’s first Advanced Water Reclamation Plant (AWRP) recently celebrated another milestone in June 2025 when it was named Jury Winner in the Factories and Warehouses category at the 13th Annual Architizer A+Awards in New York.

Selected from over 5 000 entries spanning 80 countries, the AWRP is now officially recognised as one of the best-designed buildings in the world in its category and was created by Cape Town based firm, SALT Architects in conjunction with the engineering team.

“This international award shows that South African infrastructure can lead the world not just in advanced functionality, but also in aesthetically pleasing and purposeful design,” comments Councillor Zahid Badroodien, Mayoral Committee Member for Water and Sanitation, City of Cape Town.

Situated next to the Cape Flats Wastewater Treatment Works in Pelican Park, once fully commissioned the AWRP will play a crucial role in the managed injection of treated secondary

effluent into the Cape Flats Aquifer, replenishing this vital groundwater source. This will enable the city to abstract water from the aquifer sustainably, which will then undergo further treatment at potable water treatment plants to meet SANS 241 drinking water standards.

Work on the next phase of the AWRP is currently under way, which will see the installation of mechanical and electrical components such as ozone generators, ultra-violet disinfection, pumps and filter media at this state-of-the-art facility.

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WATER & WASTEWATER

CUT CONSTRUCTION COSTS WITH ALTERNATIVE WATER SOLUTIONS Water scarcity is a growing global concern, driven by urbanisation, population growth, and climate change.

Urban water consumption is expected to rise by 62% from 1995 to 2025, with potential shortages by 2050.

T

o address this, preser ving existing water resources and reducing potable water demand is crucial. In construction, rising water costs and sustainability concerns are pushing developers to adopt alternative water sources like greywater reuse and rainwater har vesting. Integrating these systems into residential, commercial, and industrial projects helps cut costs while promoting environmental responsibility.

Why alternative water sources?

Alternative water sources were long underutilised in industry but are now gaining popularity in urban water management.

Greywater alone can cut potable water use by up to 30% in homes and 60% in commercial buildings, while reusing it for irrigation can boost household savings by 40%.

In construction, alternative water sources reduce reliance on potable water for dust suppression, concrete mixing, equipment washing, and site irrigation.

capture and store runoff. This water can be used for non-potable site activities and even potable use with proper filtration that meets SANS 241 drinking water quality standards.

Benefits: Reduces municipal water use, especially in the dry season.

2 Greywater systems

Water from baths, showers, and sinks (excluding kitchens) can be reused for nonpotable construction activities such as equipment washing, landscape irrigation or flushing toilets. Greywater systems filter and direct this water to lawns, ornamental plants or where it can be collected for use.

3 Borehole Water

Accessing underground aquifers through boreholes ensures a reliable water supply, par ticularly in areas with scarce sur face water. Although installation can be expensive, borehole water can support all construction activities requiring water and, with proper treatment, can also be used for domestic purposes.

Some alternative water sources to choose from

How alternative water sources cut costs

Maximise seasonal rainfall by installing rainwater tanks and guttering systems to

• Lower water bills: Using greywater can cut water costs by up to 50%, especially on large-scale projects that require significant

Greywater utilisation can cut potable water use by up to 30% in homes and 60% in commercial buildings

Boreholes provide a reliable water supply, particularly in areas with scarce surface water

1 Rainwater harvesting

Installing rainwater tanks and guttering systems to capture and store runoff is a highly effective conservation practice, as well as mitigating against water restrictions during drought periods

water usage. Further savings can be realised with the incorporation of other alternative water sources.

• Reduced sewer discharge fees: Reusing greywater means less wastewater enters the sewer system, lowering municipal disposal charges.

• Operational efficiency: On-site alternative water source systems reduce dependency on municipal supply, preventing costly delays during droughts or water restrictions.

• Enhanced project valuation: Sustainable practices improve a project's marketability and can elevate the overall EDGE score for green building accreditation.

Utilising alternative water sources is not just cost-effective, it is a step toward sustainable building, positioning companies as leaders in efficiency and environmental responsibility.

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38 IMIESA July 2025

PUMP SYSTEMS

High-pressure jetting and vacuum trucks: hydraulic versus v-belt pumps As municipalities and service providers demand greater efficiency, reliability, and ease of maintenance from their sewer-cleaning and industrial jetting and vacuuming equipment, hydraulic-driven pumps are increasingly becoming the standard.

A

ccording to Sebastian Werner, MD of Werner Pumps – leading local manufacturer of highpressure jetting and vacuuming trucks – although V-belt driven pumps have long been used in high-pressure jetting trucks, hydraulic technology offers numerous benefits.

“We tr y to convince all our customers to opt for the hydraulic-driven pump because it’s a more modern solution that offers better reliability, less downtime, fewer repairs and ultimately a lower total cost of ownership,” he says.

“Almost all our trucks use hydraulic-driven pumps, and we only fit the V-belt option if a customer insists on it. Even then, we’ve developed a more robust system that uses a sturdier single belt because the traditional multi-belt option means that when one belt fails, all the belts need replacing, which is costly and (in my opinion) a waste.”

Werner explains that V-belt systems are prone to wear and tear. “Belts can slip, stretch, crack, or break entirely, especially under high loads or in the dusty, wet environments that A Werner Pumps high-pressure jetting truck supplied to Swakopmund Municipality

are typical of sewer-cleaning or industrial jetting or vacuuming operations. This not only reduces performance but also increases the risk of unplanned downtime.”

Hydraulic-driven systems, by contrast, offer superior durability. “With fewer moving par ts exposed to environmental stressors, they’re less vulnerable to the mechanical failures that often plague belt-driven setups. This reliability translates directly to more uptime and greater peace of mind for operators in the field,” Werner explains.

Design, performance and maintenance advantages Hydraulic drives also offer more flexibility in equipment design. Because hydraulic lines can transmit power over a distance, pump placement is less constrained by the position of the truck’s engine or gearbox.

“This makes it easier for us to optimise the layout of components and build more compact, ergonomic truck-mounted units,” says Werner. “For example, while many of our competitors’ V-belts sit underneath the truck,

where they can easily be damaged by debris on the road or being physically knocked, the hydraulic system on our trucks sits neatly behind the operator cab. This means they are located well above the level where they could easily be damaged and offer much easier access should repairs ever be required.”

Maintenance is another area where hydraulic systems shine. While V-belts must be regularly inspected, tensioned, and replaced, hydraulic systems typically require only routine checks of fluid levels, filters, and hoses. This means fewer service interruptions and lower lifetime maintenance costs.

“Although hydraulic systems may carry a higher upfront cost, which is what seems to put some customers off, their superior durability, reduced downtime, and lower maintenance needs result in a lower total cost of ownership over time,” adds Werner.

“Especially for our customers who own and operate multiple trucks, this long-term value is a compelling reason to invest in hydraulicdriven units,” Werner concludes.

A hydraulic pump system installed on one of Werner Pumps’ high-pressure jetting trucks

IMIESA July 2025

39

BITUMEN & ASPHALT

SAT: A NEW ERA OF EXCELLENCE For more than three decades, the Society for Asphalt Technology (SAT) has been instrumental in contributing to the personal growth of a diverse range of industry specialists.

IMIESA speaks to incoming SAT President, Joanne Muller, about her journey and the ongoing quest to develop technical and professional excellence in the flexible pavement industry.

What were the steps that led to your career in the roads sector?

I was interested in how structures come together from a young age and initially considered a career in architecture.

Subsequently, however, I chose civil engineering, and in my second year of study was awarded a bursary by Murray & Roberts Engineering Solutions. At the time, Much

Asphalt formed part of the Group, and on graduating they invited me to join them.

The rest, as they say, is history, and since then my past and present focus has been dedicated to the asphalt industr y. In my current industr y role, I am the Regional Technical Manager: Gauteng Inner at Much Asphalt.

When did you join SAT and become President?

Joanne Muller, President of the Society for Asphalt Technology (SAT)

40 IMIESA July 2025

I joined in 2012 during my first year at Much Asphalt, thanks to the motivation of John Onraët and Herman Marais – both SAT Past Presidents. John currently serves as SAT’s Operations Manager.

From the onset, I was exposed to a series of mentorship oppor tunities, working across various SAT portfolios, which proved challenging and significantly influenced my appreciation for this complex industry.

A major turning point was my election as chairperson of the SAT Central Region

Committee in 2021, the latter representing Gauteng, Nor thern Province, Nor th West, Free State, Mpumalanga, Botswana and Zimbabwe – so our largest member base.

Then, some eight months later, I was elected as SAT Vice President, preparing the way for my current position as SAT President, effective May 2025. Quite a rollercoaster ride – but an exciting one.

None of this would have been possible without the support of the SAT Council, as well as the broader SAT community, and I extend my sincere thanks for this great honour. I’d also like to acknowledge our immediate Past President, Krishna Naidoo, from SANRAL, who was instrumental in preparing me for this position.

As the incoming President – and the youngest at 37 – one of my key mandates is to ensure that all our young members receive similar oppor tunities for personal growth within SAT, empowering them in their professional careers.

Do you think there’s a significance in being SAT’s first woman president?

First and foremost, I’m an engineer. However, I appreciate the need to ensure that our industry – as well as the broader construction sector – is fully representative and inclusive.

Leading by example, this has been SAT’s

BITUMEN & ASPHALT

mandate since its establishment in 1994 and today some 25% of our members are women, so there’s a positive shift. This is underscored by the fact that Nir vana Loutan is our current Vice President, plus our four Committees – representing the Central, Eastern, Southern, and Eastern Cape regions – are all chaired by women.

They ser ve as an inspiration to the next generation of women asphalt professionals.

The sky’s the limit.

What’s the relationship between SABITA and SAT? There’s a strong synergy between SAT and the Southern African Bitumen Association (SABITA), the latter representing company members, and the former individuals. SAT members are actively involved on SABITA Technical Committees in areas like the development of industry manuals, as well as on the CAPSA conference organising committee, with the next one coming up in 2027. Both organisations complement each other in fostering industry excellence.

SAT’s dedicated focus is on training and professional development across a broad range of disciplines in the road construction market, from engineers, technologists and scientists to laborator y technicians, logistics specialists and contractors.

How does SAT add value?

By becoming a member of SAT, individuals join a community of like-minded individuals, in South Africa, Southern Africa and across the globe. It’s an invaluable network and knowledge sharing hub for finding solutions to technical issues and keeping track of technological developments via practitioners and allied professional bodies worldwide.

If we look at the backlog in terms of road maintenance and new construction, it’s clear that there’s an urgent need to sustain and grow technical capacity. Currently, South Africa faces a major skills shortage due to factors like retirement and emigration, which has created a widening gap in terms of knowledge and applied experience.

Conversely, this has also led to younger professionals being promoted at a faster rate than in the past. This is reflected in our membership, with the average age of members joining in the past five years at around 34.

Alongside the need for mentorship, this is where SAT’s ECSA accredited continuous professional development (CPD) programmes prove invaluable in helping practitioners bridge technical challenges in applying fit-for-purpose solutions.

Quality and safety are non-negotiable requirements for construction. In this respect, applying best practice outcomes is enshrined within SAT’s Code of Ethics. Our mandate is to ensure that the infrastructure solutions our members deliver are in the best interests of society – both in terms of sustainability and lifecycle optimisation.

An example is the growing issue of road failures – especially our current pothole pandemic – despite ongoing repairs. The key question is whether the right techniques are being used, and if not, why not? Collectively, as an industry, we must get on top of these and other issues because they have a direct impact on lives and livelihoods.

What are SAT’s key objectives going forward?

As President, my main mission is to support the structures that make SAT function on the

ground, where the facilitation of technology transfer happens in practice. This takes place via webinars, workshops, site visits and conferences.

As in the first half of 2025, we have a comprehensive programme of regional in-person or online/hybrid events scheduled for the remainder of the year, ably directed

by John and our Committee Chairs. It must be said that SAT is a non-profit organisation and the members of the committees that make these events happen are all employed in the industr y and give their free time as volunteers to ensuring that SAT delivers excellence to its members.

Aside from classroom engagement, we’re now also placing increasing emphasis on the need for real world exposure. This includes technical tours hosted at asphalt and binder manufacturing facilities, original equipment manufacturers, quarries and roads projects.

Everyone needs to understand the complete cycle from design to construction.

How has the industry responded to the SATBinderrr initiative?

This has been one of our most successful initiatives in recent years. The first one took place in 2021 as a virtual event during the height of the COVID-19 pandemic and really pulled the industry together. Subsequently, these biennial conferences went the hybrid route to maximise local and international par ticipation in terms of delegates and speakers.

In addition to showcasing innovation, what makes SATBinderrr special is the emphasis we place on encouraging our younger members to publish and present. Although it can be a daunting process to address industr y peers, it’s amazing to see these

SAT Vice President and Regional Chairs

Nirvana Loutan, SAT Vice President

Belindar Preethapal, SAT Central Region Chair

Nishaat Mowzer, SAT Southern Region Chair

Nteseng Ramoraswi, SAT Eastern Region Chair

Juliet Asare, SAT Eastern Cape Chair

IMIESA July 2025

41

BITUMEN & ASPHALT

A SAT Eastern Cape region site visit and networking event held at East Coast Asphalt

SAT TECHNICAL TOURS Alongside classroom engagement, SAT arranges site visits to asphalt and binder manufacturing facilities, original equipment manufacturers, quarries and roads projects so that members are exposed to the multi-faceted supply chain elements that go into constructing flexible pavements

presenters grow in confidence, with a positive spin-off for their careers.

Currently, preparations are now well under way for SATBinderrr 2026, and the industry can look forward to another landmark event.

Can students become members?

Yes, of course. Logically, building our student membership base is the best way to sustain and expand SAT’s contribution to

the industry longer-term. However, it’s not purely about chasing numbers, it’s about pursuing excellence.

In this respect, SAT research shows that our industry needs to engage with students right from the onset of their studies. This enables companies to identify talent, award bursaries, provide career advice, and make provision for internships and recruitment. In turn, students gain a far greater understanding of

the career opportunities available within our multi-faceted asphalt sector.

We are also in the process of concluding agreements with various universities, which will enable us to host SAT events at their facilities. This will assist those students who cannot attend our external events (at no charge) due to time constraints and/or travel costs.

What’s the forward view?

All the signs now point to a strong surge in national, provincial and municipal roads projects over the next three years, which is great news for our industry. Within the mix, SAT has an instrumental role to play in enabling technical proficiency and best practice, spearheaded by our members.

An N3 corridor site visit hosted by the SAT Eastern Region in 2024

42 IMIESA July 2025

VEHICLES & EQUIPMENT Ngquza Hill Local Municipality Roads Foreman, Gugu Ndwabu (left), with Bell Equipment Sales Representative, Fundile Ntsinde

Ngquza Hill Local Municipality’s JCB JS305 excavator forms an integral component of its ongoing gravel road maintenance programme

Maintenance considerations Ngquza Hill Municipality She mentions that another consideration in forward planning was to obtain as much turns to Bell to boost its fleet their yellow machine equipment as possible from

The Ngquza Hill Local Municipality in the Eastern Cape has invested in its yellow machine fleet, adding two excavators and a Bell articulated tractor over an eighteen-month period. This follows a decision by the municipality’s council that the maintenance of roads and other infrastructure should take place in-house and, as far as possible, without the use of contractors.

T

he municipality lies in one of the most picturesque parts of the Eastern Cape, where deep valleys separate towering hills, with traditional homesteads dotting the countryside.

The municipality serves both Flagstaff and Lusikisiki and there are 32 voter wards across the two towns. In total, some 333 000 people live there, according to the most recent census.

The Ngquza Hill Local Municipality’s Technical Manager, Asanda Hlehliso, is a qualified civil engineer with postgraduate qualifications, and in an ideal position to explain the municipality’s many duties. “We as the technical department oversee the maintenance and repair of much of the infrastructure in both Flagstaff and Lusikisiki, which includes public spaces, parks, sports fields, cemeteries, solid waste dump sites and a massive 981 km of gravel roads,” she explains.

“The gravel road network is vitally important as it grants our citizens access to their homes, schools and places of business, relaxation and worship. When the council decided that we were to do the maintenance ourselves, we realised that we’d need to add to our yellow equipment fleet to do this effectively.”

Needs analysis Asanda, in her capacity as department head,

put together a technical committee consisting of herself and colleagues Pathuo Nqezo, the Senior Roads Foreman, and Gugu Ndwabu, the Roads Foreman, to do a needs analysis of what equipment was most urgently needed.

They decided they most needed an excavator.

Fortunately, the Ngquza Hill Local Municipality could leverage an RT57 agreement with Bell Equipment and, through the supplier’s Public Sector Sales Representative, Fundile Ntsinde, they gained valuable insight into what excavator model would work well for them.

“Working with our supply chain division, we put forward criteria such as price, availability, technical backup and previous experience – all conditions which Bell Equipment met easily.

Although we initially thought to buy a 20-ton excavator, Fundile recommended that we rather consider a 30-ton machine that could handle heavier work, given the vast number of roads we have to maintain, as well as water and drainage infrastructure that was under pressure with the recent heavy rainfalls,” Asanda continues.

Their choice ultimately fell on a JCB JS305 excavator, which was delivered on 26th October 2023, and they are not disappointed. “We’re happy that we trusted Fundile’s advice as we’re extremely satisfied with the JCB JS305 excavator’s performance,” says Asanda.

one supplier to smooth the way forward for the mechanic position, which was recently filled.

“We believe that we’ll reduce potential downtime on machine servicing and repair if we must only deal with one supplier and it should make the keeping of essential consumable spares and service kits easier. In this case we’d be well satisfied if that supplier could be Bell Equipment in keeping with the older Bell 770G grader and Bell 315SL backhoe loader that we already have. We’re also confident that with Bell Equipment having a well-stocked depot in nearby Mthatha, our machines’ maintenance will be prioritised.”

Roads Foreman, Gugu Ndwabu adds: “Our operator took to the JCB JS305 excavator easily and repor ts that the controls are smooth and responsive. We’ve been excavating road-fill material that it loads into tipper trucks and despite this relatively heavy and constant work, the machine’s miserly fuel burn has surprised us as we’re averaging around 19,6 litres an hour.”

The municipality followed up with a Kobelco SK220XD-10 excavator at the end of May 2024 and a Bell 2304E articulated tractor in February 2025. The Kobelco excavator was delivered to the Lusikisiki landfill site for refuse removal, waste disposal, and excavating of the site, while the Bell articulated tractor is used in the Flagstaff area for crushing and compacting soil on gravels roads.

“These are challenging yet exciting times for us in the Technical Department and we’re cer tainly setting out to not disappoint our principals and the citizens of our towns in terms of our commitment to service delivery,” Asanda concludes.

IMIESA July 2025

43

VEHICLES & EQUIPMENT

Through early involvement, Mammoet's team was able to provide valuable recommendations for adapting the layout of the CCU plant to the requirements of the installation. Additionally, the space requirements were integrated into the overall construction site logistics. This later enabled a safe, efficient, and smooth execution, saving the customer time and costs.

Lifting phases

Heavy lifting of the absorber column

A case study in 3D engineering and heavy lifting The construction of the first large-scale carbon capture and utilisation (CCU) plant in Germany at Heidelberg Materials’ Lengfurt facility required a series of heavy lift solutions provided by Mammoet.

D

ue to its engineering expertise and many years of experience, Mammoet was requested by Linde Engineering to develop a lifting and installation concept for various large components for this groundbreaking Capture-toUse (Cap2U) project. The latter is a joint venture between Heidelberg Materials and Linde.

Erecting the absorber column for the CCU plant

First, the 100 t CCU absorber column was erected on the pre-dressing area using a tandem lift. The load was swung almost 180 degrees on the hook of the crawler crane and moved approximately 20 m to the installation position.

There, the column had to be carefully guided behind a building before it could be positioned, aligned, and bolted onto the foundation in the steel structure.

Due to the 55 m length of the absorber column and the high complexity of the lifting process, this was the most challenging heavy lift. Following this, the 67 t stripper column, four tanks each weighing 72 t, and the 178 t heat exchanger were installed.

Lifting advantages The confined space and many different contractors required precise planning of workflows, inter faces, and construction progress. A feasibility study was conducted a year before the start of the execution, in which various solution options were analysed and examined in detail.

Using a 3D model of the existing cement plant, Mammoet's team was able to leverage its own engineering platform, Move3D, to visualise the complex processes, space requirements, and potential interfering edges at the confined construction site. In this respect, Mammoet’s use of a 750 t crawler crane proved to be the most flexible and efficient method of lifting and installing the large components.

Mammoet's crawler crane solution offered several crucial advantages. The crawler crane was flexible enough to safely lift loads of varying sizes and weights over long distances. This meant intermediate transport on the construction site could be avoided.

To allow for the preinstallation and parallel construction of the steel structure, the configuration of the crawler crane was also changed shortly before the project began, which saved additional time.

The early involvement of Mammoet, 3D engineering, close supervision of the execution by the planning engineers on-site, as well as the open, solution-oriented, and trustful collaboration significantly contributed to a successful project.

Heavy lifting of the stripper column on the confined construction site

CEMENT & CONCRETE

One of the most critical decisions at the start of any project is the selection of building materials

Koena Sesele, AfriSam National Sales Manager - Inland

With the right support, tools and advice contractors can navigate the challenges of the industry and grow stronger businesses

AfriSam builds contractor success with more than just cement In South Africa’s highly competitive construction industry, contractors are under pressure not only to deliver quality projects but to remain financially viable in the face of tight margins and unpredictable challenges.

A

friSam, a leading supplier of construction materials, recognises that success requires more than just products – it calls for genuine support, technical expertise and long-term partnerships.

Koena Sesele, AfriSam’s National Sales Manager - Inland, highlights how narrow profit margins leave little room for error. Delays, rework or slow payments can severely affect cash flow, making quality and efficiency crucial from the outset. Choosing the right cement, for example, can have a direct impact on cost and performance.

“Not all cements are created equal,” says Sesele. “With AfriSam’s high quality products, you can achieve more with less, reducing the amount of cement required per mix while ensuring strength and consistency.”

Technical support and skills development AfriSam suppor ts its products with comprehensive technical expertise. Its Centre of Product Excellence and team of technical consultants offer guidance on mix designs and material optimisation, helping builders produce durable concrete that meets project demands.

Technical specifications are clearly printed on every bag of cement, and additional resources are available online to assist contractors on site.

The company is also committed to skills development. Through ongoing training programmes, AfriSam helps upskill contractors on construction methods, material use and best

practices. Digital tools such as online “how-to” guides and a material calculator further support accurate planning and help prevent wastage.

ClickToGo For contractors managing their own operations, the ClickToGo digital platform enables real-time account access, simplified ordering, secure payments and delivery tracking, reducing admin and improving responsiveness.

Recognising that access to working capital is often a hurdle, AfriSam offers flexible purchasing options. Contractors can apply for credit (subject to guarantees) or make secure cash purchases online. Deliveries can be scheduled in phases to conserve cash flow, and for bulk cement needs, delivery in silos enhances efficiency.

Sesele encourages early engagement with AfriSam, even from the quoting stage, to unlock the full benefit of the company’s support.

“When we get involved early, we can help builders make smart choices that reduce risk, save money and improve project outcomes,” he says. “It is also about credibility – having AfriSam as a partner reassures clients of your professionalism.”

At the heart of AfriSam’s approach is a commitment to building long-term relationships.

“We are not just a supplier; we are a partner in every sense,” Sesele concludes. “By combining quality products, expert advice and practical solutions we are helping contractors succeed in a tough market and build stronger businesses for the future.”

AfriSam backs its products with deep technical knowledge

In construction the best results come not from the cheapest option, but from the most considered choices

AfriSam’s ClickToGo platform offers realtime account management, streamlining processes such as order placement, payment and delivery tracking

IMIESA July 2025

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IMESA AFFILIATE MEMBERS

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Consulting En ineers

AECOM siphokuhle.dlamini@aecom.com AFI Consult banie@afri-infra.com ARRB Systems info@arrbsystemssa.com Asla Construction (Pty) Ltd johanv@asla.co.za BMK Group brian@bmkgroup.co.za Bosch Projects (Pty) Ltd mail@boschprojects.co.za BVI Consulting Engineers marketing@bviho.co.za Camjet info.jhb@camjet.co.za CCG puhumudzo@ccgsytems.co.za / info@ccgsystems.co.za Civtech Engineers (Pty) Ltd admin@civtech.biz Corrosion Institute of Southern Africa secretary@corrosioninstitute.org.za Dlamindlovu Consulting Engineers & Project Managers info@dlami-ndlovu.co.za EFG Engineers info@efgeng.co.za Elster Kent Metering Mark.Shamley@Honeywell.com EMS Solutions paul@emssolutions.co.za ENsync Engineers info@ensync.africa ERWAT mail@erwat.co.za Gabion Baskets mail@gabionbaskets.co.za GIBB marketing@gibb.co.za GIGSA secretary@gigsa.org GLS Consulting info@gls.co.za Gorman Rupp Cordeiro@gormanrupp.co.za Gudunkomo Investments & Consulting info@gudunkomo.co.za Hatch Africa (Pty) Ltd info@hatch.co.za HB Glass Filter Media info@hardybulkinglass.com Herrenknecht schiewe.helene@herrenknecht.de HSA Technology (Pty) Ltd cs@hubersa.com Hydro-comp Enterprises info@edams.co.za IMQS Software (Pty) Ltd shemine.adams@imqs.co.za Infrachamps Consulting info@infrachamps.co.za INFRATEC info@infratec.co.za Institute of Waste Management of Southern Africa iwmsa@iwmsa.co.za IQHINA Consulting Engineers & Project Managers info@iqhina.co.za iX engineers (Pty) Ltd hans.k@ixengineers.co.za Izinga Holdings info@izingalabezi.co.za JG Afrika DennyC@jgafrika.com KABE Consulting Engineers info@kabe.co.za Kago Consulting Engineers kagocon@kago.co.za Kantey & Templer (K&T) Consulting Engineers ccherry@ct.kanteys.co.za Kitso Botlhale Consulting Engineers info@kitsobce.co.za KSB Pumps and Valves (Pty) Ltd salesza@ksb.com KUREMA Engineering (Pty) Ltd info@kurema.co.za Lektratek Water general@lwt.co.za Loshini Projects muzi@loshini.co.za m4a fagan@m4a.co.za Makhaotse Narasimulu & Associates mmakhaotse@mna-sa.co.za Mariswe (Pty) Ltd neshniec@mariswe.com Martin & East gbyron@martin-east.co.za M & C Consulting Engineers (Pty) Ltd info@mcconsulting.co.za Mhiduve adminpotch@mhiduve.co.za MPAMOT (Pty) Ltd mpumem@mpamot.com Mvubu Consulting & Project Managers miranda@mvubu.net NOTHI Group info@nothigroup.co.za NTGR Engineering info@ntgr.co.za Nyeleti Consulting naidoot@nyeleti.co.za Prociv Consulting & Projects Management amarunga@prociv.co.za Rainbow Reservoirs quin@rainbowres.com Re-Solve Consulting (Pty) Ltd maura@re-solve.co.za Ribicon Consulting Group (Pty) Ltd info@ribicon.co.za Royal HaskoningDHV francisg@rhdv.com SABITA info@sabita.co.za SAFRIPOL mberry@safripol.com SAGI annette@sagi.co.za SALGA info@salga.org.za SAPPMA admin@sappma.co.za / willem@sappma.co.za SARF administrator@sarf.org.za.co.za marketing@sbstanks.co.za SBS Water Systems Silulumanzi Antoinette.Diphoko@silulumanzi.com Siroccon International (Pty) Ltd admin@siroccon.co.za SiVEST SA info@sivest.co.za Sizabantu Piping Systems (Pty) Ltd proudly@sizabantu.com Siza Water (RF) Pty Ltd PA@sizawater.com Sky High Consulting Engineers (Pty) Ltd info@shconsultong.co.za SKYV Consulting Engineers (Pty) Ltd kamesh@skyv.co.za Smartlock jp.alkema@smartlock.net SMEC capetown@smec.com SOUTH AFRICAN VALUE EDUCATION Sabiha@savegroup.co.za Southern African Society for Trenchless Technology director@sasst.org.za SRK Consulting jomar@srk.co.za Structa Group info@structatech.co.za Superior Filtration (Pty) Ltd info@superior-filtration.com TPA Consulting roger@tpa.co.za Ultra Control Valves peter@ultravalves.co.za V3 Consulting Engineers (Pty) Ltd info@v3consulting.co.za Videx Storage Tanks sales@vidextanks.co.za VIP Consulting Engineers esme@vipconsulting.co.za VNA info@vnac.co.za Water Institute of Southern Africa wisa@wisa.org.za Wam Technology CC support@wamsys.co.za Wilo South Africa marketingsa@wilo.co.za WRCON ben@wrcon.co.za Zimile Consulting Engineers info@zimile.co.za Zutari charmaine.achour@zutari.com

CEMENT & CONCRETE

Through the use of tailored polymers and catalysers to enhance performance, EnviroMix® reduces CO₂ emissions by up to 50% per m3 of concrete Chryso’s R&D teams develop customised EnviroMix® solutions using precise material analysis to deliver sustainable high performance concrete formulations

EnviroMix® speeds up early strength development, lowering costs associated with formwork, scaffolding and labour

PRODUCING SUSTAINABLE CONCRETE WITHOUT CONSTRUCTION DELAYS

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s the construction industry intensifies its focus on sustainability, a common challenge has been balancing lower carbon emissions with the need for fast-paced project delivery. Chryso is addressing this issue with its EnviroMix® range – a solution that allows for the use of low carbon concrete without sacrificing early strength performance.

“Reducing the carbon footprint of buildings is no longer optional – it is becoming a priority for developers and specifiers,” says Patrick Flannigan, Chryso GM Technical and Product Support Management Africa. “But traditional methods for lowering embodied carbon, such as replacing ordinary Portland cement with supplementary cementitious materials (SCMs), typically slow down early strength development.”

This trade-off can cause costly delays on site as slower strength gain means formwork and scaffolding must remain in place longer. It also limits turnaround times in precast manufacturing, where production speed is key to profitability.

Chryso’s EnviroMix® range effectively resolves this challenge. Designed to support concrete mixes with high SCM content – such as fly ash or ground granulated blast furnace slag – EnviroMix® ensures that early strength targets are still reliably achieved.

Backed by a strong global track record, Chryso’s low carbon solutions were responsible for avoiding 15 million tonnes of CO₂ emissions in 2023 alone.

The company’s laboratories also offer customised formulations, tailored to the variability of locally sourced SCMs, ensuring consistent results.

“With EnviroMix®, sustainable concrete no longer means a compromise on productivity or quality,” adds Flannigan. “It is a vital step toward greener construction – made practical, reliable and economically viable.”

IMIESA July 2025

47

PERMEABLE PAVING

Terraforce’s Terracrete permeable hard lawn concrete paver system installed at Bayview Holiday Village

Eco-friendly Terracrete pavers help preserve Ningaloo coastal zone

The Terracrete system can be used in a wide range of applications that include light erosion control on exposed earth slopes, stormwater channel lining, and paved road/parking surfaces

Along Western Australia’s pristine coastline, approximately 1 400 km north of Perth, lies Coral Bay – a gateway to the World Heritagelisted Ningaloo Reef. This seasonal tourist destination, with its caravan parks, hotel, and chalets, sees its population surge to around 4 000 visitors during the peak season from May to November.

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uilt on coastal sand dunes, the area’s infrastructure originally relied on imported “salt marsh” clay for roads, caravan sites, and parking areas. However, while this material dried to a hard surface, it became dangerously slippery when wet and produced significant dust during dry periods.

In a groundbreaking initiative in 2007, Bayview Holiday Village – the largest resort in the area – became the first in the region to trial Terraforce® TerracreteTM permeable pavers as an innovative solution. This test installation, supplied by Geraldton-based Terraforce licensed manufacturer, The Blockmakers, marked the beginning of a significant environmental improvement for the area’s infrastructure.

Says Tracey Foster at The Blockmakers: “The Terracrete blocks were manufactured with a special Coral Bay mix design to suit this application. Visiting in February 2025, we were impressed with how well the pavers have handled all traffic since 2007.”

installed. Testament to the benefits of Terracrete was evident during cyclone Olwyn in 2016. The torrential rains that accompanied Olwyn were successfully absorbed on site with no runoff into the bay.”

The resorts next to Bayview – Peoples Caravan Park and Ningaloo Coral Bay Resort – realised the value of the Terracrete blocks after this cyclonic event and have subsequently also installed them on their roads, with works ongoing.

runoff that threatened the delicate coral ecosystem in the bay. Local contractor, Coral Bay Contracting, handled the installation process.

“The first step was to remove the ‘salt marsh’ and create a porous base to allow for better water absorption. Approximately 1 600 m² of Terracrete pavers were laid in the caravan park during the off-season,” explains John Farne of Coral Bay Contracting.

John adds that the results were better than expected: “Bayview have continued to use the Terracrete blocks throughout their resort – and approximately 12 000 m² has currently been

Sustainability in action This infrastructure change from impermeable traditional clay surfaces to a Terracrete permeable paver eco-surface directly protects the coral reef by preventing sedimentation, nutrient pollution, and thermal shock, while allowing natural water filtration through the ground. It also serves as a sustainable solution that enhances the living experience for visitors at Coral Bay’s resort facilities.

Integrated tiled pathways were incorporated into the Terracrete block layout at the Ningaloo Coral Bay Resort

Staircases tying in with Terracrete paving at the Ningaloo Coral Bay Resort

Reducing stormwater velocities The primary objectives were to clearly define roadways and, more crucially, reduce stormwater

INDEX TO ADVERTISERS APE Pumps & Mather+Platt CFAO Equipment Hall Longmore IMESA

48 IMIESA July 2025

IFC OFC, 6 12 2, 4, 33, 46

JPCE

35

Rainbow Reservoirs

37

Rand Water SAPPMA

14, 38 17

Structa Group Ultra Control Valves Uretek

21, 25 10 OBC

IMESA The official magazine of the Institute of Municipal Engineering of Southern Africa www.imesa.org.za

INFRASTRUCTURE DEVELOPMENT • BUILDING • MAINTENANCE SERVICE DELIVERY • UTILITIES MANAGEMENT • ROADS • ENERGY

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